Polaris FS Classic Owner'S Manual Download Page 91

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MAINTENANCE

Periodic Maintenance Interval Table

= Perform Service

= Replace

DAILY

PRE-

RIDE

INITIALLY

(km)

YEARLY

or EVERY

(km)

Item

Instructions

(see referenced pages)

150

(240)

500

(800)

1500

(2400)

Engine Stop Switch

71 Test for proper operation. Do not

operate if switches fail see your

Ignition Switch

p p

operate if switches fail, see your

dealer for service.

Throttle Safety

Switch

dealer for service.

Taillight

71 Test for proper operation, replace

bulbs as needed

Brakelight

p p

, p

bulbs as needed

Headlight

Skags (Wear Bars)

127 Inspect for wear or damage, replace

when worn

Fluid Leaks

Inspect for fluid leaks

Parking Brake

68 Test for proper engagement and re-

lease, see your dealer for service

Brake Lever

67 Check lever travel and lever “feel”

Coolant

106 Inspect level, add as needed

Brake fluid

112 Inspect fluid level, add as needed

CHANGE EVERY 2 YEARS

Hood Latches

66 Secure properly, replace if damaged

Seat Latches

65 Secure properly, replace if damaged

Rail Slide

124 Inspect for wear or damage, replace

when worn

Foam Oil Breather

Element

97 Check pre-ride, clean or replace

with each oil change. Clean after tip-

ping 3 times onto left side.

Front/Rear

Suspension and

Steering Fasteners

70 Inspect for missing or loose bolts

and fasteners, tighten or replace as

needed

WEEKLY / BEFORE LONG TRIPS

Front Limiter Strap

Inspect for wear, damage and miss-

ing or loose fasteners, replace as

needed

WEEKLY / BEFORE LONG TRIPS

Oil Lines

Inspect, replace if worn or damaged

Alternator Belt

104 Check tension and condition,

replace if worn or damaged

Summary of Contents for FS Classic

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Page 3: ...m this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm onto the snow on which they operate Keep this engine properly tuned and avoid unnecessary...

Page 4: ...d For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and ...

Page 5: ...s in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole...

Page 6: ... of your snowmobile s controls and features The Perfect Fit 46 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 64 This section explains procedures that must be performed before riding Operation 73 This section explains proper engine break in operation of features and general operating procedures Maintenance 85 This section...

Page 7: ...4 ...

Page 8: ...resentations Your model may differ Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage Protect a...

Page 9: ...f our environment Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that snowmobiles conform to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or r...

Page 10: ...in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number Tunnel VIN L Engine Serial Number on valve cover Key Number L ...

Page 11: ...t symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note w...

Page 12: ... snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile ma...

Page 13: ...behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures Stay Clear of Engine Never attempt adjustments with the engine running Turn off the ignition raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its op...

Page 14: ...r your safety always ride in a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the conditions you may encounter Such equipment may include but is not limited to extra clothing a sleeping bag a flashlight food and ...

Page 15: ...ury Always wear an approved helmet and eye protection Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Cargo Overload Touring Too much weight on the rear of the machine may reduce your ability to steer Do...

Page 16: ...ith two people on board More space is required to make turns and longer distances are needed for stopping Make sure the passenger remains seated behind the driver facing forward with both feet placed firmly on the running boards Slow down and avoid jumping your snowmobile Snowmobiles designed for two riders should never be operated with more than two people on board When traveling with a passenger...

Page 17: ...by 1 5 will equal the approximate number of feet per second your snowmobile travels If your speed is 40 MPH your snowmobile is traveling about 60 feet per second If you look back for only two seconds your snowmobile will travel about 120 feet If your speed is 60 MPH your snowmobile will travel about 180 feet in two seconds Traveling at night requires extra caution Check headlight and taillight to ...

Page 18: ...d of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or highways Steep embankments may also hide your view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Avoid travelling on frozen bodies of water When teaching inexperienced operators to r...

Page 19: ... flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in mountainous terrain Before riding in mountainous terrain call or log on to your local avalanche advisory to get current weather and snow stability information For more information about avalanche traini...

Page 20: ...orm this check in both the full up and full down steering positions Driving Downhill When riding downhill shift your weight to the rear of the snowmobile and reduce your speed to a minimum Apply just enough throttle to keep the clutch engaged allowing the engine s compression to help slow the snowmobile and keep it from rolling freely downhill WARNING When driving on long downhill stretches pump t...

Page 21: ...n If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible rollover Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you re unable to cont...

Page 22: ...speeds Each clutch is dynamically balanced before installation Any tampering may disrupt this precision balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time especially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the ...

Page 23: ...brication will lead to overheating of the slide rail and track causing premature wear damage and failure which can result in serious injury Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating for prolonged periods on ice hard packed surfaces or roads Operating in Deep Snow If the snowmobile becomes stuck in...

Page 24: ...or s certificate For their protection as well as yours make sure they take a snowmobile safe ty course Everyone can benefit from the course S Don t jump your snowmobile Jumping may injure your back be cause of spinal compression The seat and suspension of your snow mobile have been designed to provide protection under normal riding conditions Your snowmobile is not intended for this kind of use S ...

Page 25: ...3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min 5 min WIND CHILL CHART C Wind Speed in KPH Actual Thermometer Reading C 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 Equivalent Temperature C Calm 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 3 0 7 11 14 18 22 25...

Page 26: ... replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Clutch Cover Warning This warning decal is found under the hood on the clutch cover Warming Do not operate with hood open Do not attempt adjustment with engine running Do not operate engine with plenum belt guard removed Never run engine with drive belt removed Never service clutches...

Page 27: ...NGER Passenger Warning Snowmobiles designed for an operator and one passenger have a warning decal at the right side of the steering post For more information on operating with a passenger see page 13 Warming This vehicle is designed for operator and ONE passenger only Track Warning Warming Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result ...

Page 28: ...rol always S Look behind before and while backing S Avoid sharp turns S Shift to or from reverse only when stopped S Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse S Machine stopped and engine at idle push yellow button on LH control to reverse Flashing light on dash indicates reverse opera tion S Push button again to return to forward ...

Page 29: ...nd adequate clothing while operating this vehicle S This vehicle is designed for adult use only Check local laws for age require ments S When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control the vehicle S When operating on hard packed snow ice or when crossing roads steering and braking abili...

Page 30: ...dshield 6 Handlebar 7 Operator Seat 8 Passenger Seat Touring 9 Passenger Grab Handle 10 Grab Handle Heater Switch Touring 11 Trunk Cover or Storage Compartment 12 Taillights 13 Rear Bumper 14 Snow Flap 15 Track 16 Suspension 17 Skis 18 Nosepan 14 6 5 3 2 1 7 12 15 16 18 17 13 11 9 8 4 10 ...

Page 31: ...MFD Multi Function Display 7 Engine Stop Switch 8 Throttle Control 9 Hood Hold Down Straps 10 Parking Brake 11 Handlebar Grip Warmer Switch 12 Thumbwarmer Switch 13 Electronic Reverse Button 14 MFD Control 15 Headlight Dimmer Switch 16 Mountain Bar if equipped 1 7 8 3 5 6 9 4 16 2 15 10 11 12 13 14 ...

Page 32: ...re removeable to provide open storage for transporting larger items 1 Remove the trunk cover 2 Push down on the seat latch lever C which is located at the lower rear of the passenger seat 3 Lift up the seat and remove it from the chassis 4 Reverse the procedure to reinstall the seat and trunk cover Under Seat Storage Switchback Lift the seat lever and lift the seat to access the under seat storage...

Page 33: ...Cargo Rack Switchback The maximum weight capacity for the cargo rack is 15 lbs 7 kg Always secure cargo before operating Do not exceed the rack weight limit Do not allow a passenger to sit on the seat back or the cargo rack Adjustable Headlights Adjust the headlight beam by moving the adjuster to the left or right ...

Page 34: ...ny other snowmobile components at any steering position AND at any RIDER SELECT position Do not use RIDER SELECT positions 6 or 7 unless riding conditions require it Operation in positions 6 or 7 can reduce vehicle handling for other types of riding and result in serious injury or death Choosing the Best RIDER SELECTt Position Position Riding Style 1 2 3 Relaxed Trail Riding Rider weight is slight...

Page 35: ...ion WARNING Do not lubricate the RIDER SELECT mechanism Doing so could cause loss of control and result in serious injury or death The RIDER SELECT mechanism is lubricated for life at the factory WARNING Some aftermarket accessories including windshields and cargo bags may interfere with the handlebar Such accessories could limit your ability to steer the vehicle and or may contact the brake lever...

Page 36: ...he turbo boost regulation system This may be caused by damaged or disconnected hoses between the turbocharger and wastegate solenoid pulse valve located on the engine side of the airbox or between the wastegate actuator located under the turbocharger and wastegate solenoid pulse valve If the hose has no damage and is not disconnected see your dealer immediately CAUTION Serious engine damage may oc...

Page 37: ...1 50 speed Maximum vehicle speed Max speed limiter 186 299 Engine Speed is Limited Cause Function Maximum RPM Result Reverse is selected speed sensor error Reverse 5300 Defective rollover switch speed sensor error Rollover 6000 Engine will misfire Throttle stuck throttle lever depressed speed sensor error Throttle stuck throttle safety switch high 5450 Engine will misfire at higher engine speed Th...

Page 38: ...p flashes when i g overheat lamp 32 46 51 74 221 212 105 100 p engine temperature exceeds table values 47 75 75 120 212 203 100 95 exceeds table values Above 75 120 203 95 Flashing h t l 0 31 0 50 239 115 Lamp flashes and i i fi h g overheat lamp with 32 46 51 74 239 230 115 110 p engine misfires when engine temperature with engine misfire 47 75 75 120 230 221 110 105 engine temperature exceeds ta...

Page 39: ...f the engine safely If the system senses detonation beyond a preset limit it retards ignition timing and adds fuel to reduce the detonation and prevent engine damage When the detonation returns to a permissible level the system will return spark and fuel to normal allowing the engine to run at rated power levels Sensor Fail Safe The DET includes a sensor fail safe system to prevent the engine from...

Page 40: ...cation Item 1 RPM or Speed Altitude if equipped Service Interval 2 Electrical System Voltage Level 3 MAX Maximum MPH KPH or RPM MPH Miles per hour KPH Kilometers per hour RPM Engine crankshaft revolutions per minute 4 Air Temp if equipped Engine Temp Degrees Celsius Degrees Fahrenheit 5 Miles Kilometers 6 Hours Trip 1 Trip 2 Trip F Service Label Altitude Label 7 Fuel Level FS or Turbo Boost FST 1 ...

Page 41: ... MPH KPH or temperatures press and hold the MODE switch until the unit of measurement changes about 10 seconds Speedometer Tachometer The speedometer and tachometer can be viewed in either the analog or the digital display If the analog display is set to show speedometer readings the digital screen will automatically display the tachometer option 1 If the analog is set to show the tachometer the d...

Page 42: ... odometer Trip 1 Trip 2 Trip F and Clock settings Trip Settings Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled 1 To reset a trip odometer to zero enter the Trip 1 or Trip 2 display 2 Press and hold the SET button for two seconds Trip F automatically displays if the fuel level is low The fuel symbol and the last fuel bar on the MFD gauge will blink ...

Page 43: ...hin ten seconds the clock will automatically save the new entry Engine Program The Engine Program automatically displays the engine coolant temperature engine hours electrical system voltage level and fuel level On machines equipped with altimeter sensor and ambient air temperature sensors altitude and ambient air temperature will display as additional screens in the engine program Press the SET b...

Page 44: ...thin 50 ft 15 m of current altitude NOTE The gauge reads barometric pressure and allows the rider to compensate for daily fluctuations in air pressure The gauge can adjust the displayed altitude to 1300 ft 396 m from the preset value It will adjust up to 1300 ft 396 m above the calibrated altitude Once the 1300 ft 396 m offset has been reached the next adjustment is 1300 ft 396 m from the calibrat...

Page 45: ...History Program is not currently displayed The History Program will display the history of the Maximum Speed Maximum RPM and Service Interval settings Maximum Speed RPM Reset While in either the MAX MPH or the MAX RPM mode press and hold the SET button for three seconds to reset the recorded maximum values for both MPH and RPM Both of these values are reset at the same time Reset the MAX MPH RPM v...

Page 46: ... reset the reminder at the existing interval 1 Enter the service interval screen 2 Press and hold the SET button for ten seconds continuing to hold even after the display begins to flash 3 When the display stops flashing release the button The service interval has been reset To reset the reminder at a new interval 1 Enter the service interval screen 2 Press and hold the SET button for five seconds...

Page 47: ...refully cut the bottom of the compartment opposite the wires to separate the heat sealed seams Squeeze the corners of the compartment inward so the battery C is visible NOTE Note the orientation of the battery before removing it An incorrectly installed battery will not maintain the clock 5 Using needle nose pliers grasp the battery and rotate it slightly so the leading edge of the battery is rais...

Page 48: ...able tie was located Make sure the battery wires are not stretched tight Gauge Cleaning 1 Wipe the gauge face as needed using a clean cloth and a mild soap and water solution Wipe dry with clean soft cloth 2 Clean the back side of the gauge using a clean cloth and a mild soap and water solution Do not remove the electrical connectors or protective rubber boot Do not spray the back side of the gaug...

Page 49: ...omizing each adjustment individually to suit rider preference The snowmobile should be methodically tested one change at a time under the same conditions trail and snow conditions vehicle speed riding position etc after each adjustment until the best ride is achieved IFS Components 1 Skis 2 Front shocks and springs 3 Rod ends 4 A arms IFS Adjustment Options S Shock damping if equipped with ArvinMe...

Page 50: ... occurs turn the screw clockwise to increase compression and stiffen the ride When adjusting these shocks we recommend that you turn the screw only 1 4 turn at a time then test ride Always adjust both shocks equally Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions Please see your Polaris dealer for assistance before attempting to adjust pr...

Page 51: ...ound knowledge of mechanical theory tool use and shop procedures to perform the work safely and correctly Shocks contain high pressure nitrogen gas Use extreme caution when handling high pressure service equipment We recommend that this work be performed by a Polaris dealer Front Springs The front springs can be changed if spring preload alone isn t sufficient and further adjustment is desired to ...

Page 52: ...ce see your dealer Suspension Performance Tips S Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride S In deep snow a new rail slide will offer improved perf...

Page 53: ...re the distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y from X Sag X Y Adjust sag by rotating the torsion spring preload cams located on the rear torque arm See illustration The ideal amount of sag for this rear suspension is five inches 12 7 cm X Y 5 in 12 7 cm...

Page 54: ...Contact your dealer for more information A Soft Tension long end of cam to front B Medium tension short end of cam up C Firm tension long end of cam up Limiter Strap Position The following information is provided only as a guideline to be used for initial suspension set up Your set up may vary based on your desired riding style A Limiter strap in high position increases ski pressure B Limiter stra...

Page 55: ...nsion Rear Track Shock Compression Damping A Turn rear track shock screw clockwise to stiffen compression B Turn the rear track shock knob clockwise for a softer ride C Turn the rear track shock knob counter clockwise for a stiffer ride B C A ...

Page 56: ... turn the adjuster slightly then test ride The recommended setting for this shock is eight 8 clicks counter clockwise FOX Zero Pro XC Shock The FOX Zero Pro XC shock is standard on the Switchback model Turn the adjustment knob L on the shock reservoir to make adjustments to the compression damping ...

Page 57: ...d position to its loaded height with the rider seated on the snowmobile Too much sag will result in bottoming and too little sag will result in reduced rider comfort Sag is used to control ride quality and rebound travel On this suspension sag is controlled by two settings the full range adjuster FRA position and the rear spring preload 1 To check sag raise the rear bumper until the suspension is ...

Page 58: ...ght Settings 3 Subtract Y from X and you will have the SAG setting X Y sag setting Example 21 17 4 The correct amount of SAG for the FAST M 10 rear suspension is 3 4 inches 8 10 cm If the measured sag is incorrect adjust the FRA position and rear spring preload See pages 56 57 X Y ...

Page 59: ... To adjust loosen the hex bolts A attaching the rear lower shock cross shaft to the rail beam 3 Using a 9 16 wrench loosen the jam nuts B on the preload bolts 4 Adjust the preload bolts C to the desired FRA position 5 Tighten the jam nuts NOTE Make sure the preload bolt contacts the slide block before tightening the jam nut 6 Tighten the hex bolts and torque to 35 ft lbs 47 Nm NOTE When the M 10 s...

Page 60: ...to adjust the preload and change the sag See your Polaris dealer for assistance OPTIONAL RETAINERS Retainer Insert Part Number Retainer Part Number Preload Sag 5436109 5135077 standard on M10 128 Least Most 5134923 Middle Middle 5135080 standard on M10 136 Most Least NOTE Whenever ordering any of the retainers listed in the chart always order the retainer insert as well The insert is not removeabl...

Page 61: ...efers comfort or control Lean toward the 4 setting for comfort and toward the 3 setting for aggressive riding 2 For full hole adjustments remove the 5 16 nut and flat washers from the lower attachments of the limiter straps and relocate the straps to the desired position i e move from position 4 to 3 Replace the nut and washer Tighten securely 3 For half hole increments such as 3 4 the limiter str...

Page 62: ...hich will affect SAG height and reduce rear suspension travel Initial M 10 Suspension Set up Charts These charts are a guideline to be used for initial suspension set ups Your set up may vary based on your desired riding style M10 128 Rider Weight with Gear lbs Suggested FRA Range Lower Number is Softer Under 100 1 to 1 1 2 100 150 1 1 2 to 2 150 200 2 to 2 1 2 200 250 2 1 2 to 3 250 300 3 to 3 1 ...

Page 63: ...ench loosen the four nuts D on the bottom of the adjuster block turn handlebar to left or right for access to back nuts NOTE If necessary pry the blocks apart with a screwdriver 3 Adjust the handlebar to the desired height Be sure handlebars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when turned fully to the left or right...

Page 64: ...l the knob assemblies and tighten securely Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable Use only Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in S Non compliance with government industry requirements S Voiding of warranty S Injury to self or others This applies but is ...

Page 65: ...lack of clearance between upper carrier wheels and track Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tunnel Track studding will enhance braking control on hard packed snow or ice but extreme caution is still required on such surfaces Steering ability may be reduced on hard packed snow or ice When stud...

Page 66: ...ntain a proper balance between the number of studs and the length of carbide on the skags the more studs you use the longer the carbide on the skags should be See your dealer s track studding chart Wear Strips To avoid excessive tunnel wear tunnel wear strips must be installed whenever track studding is used Install the appropriate wear strip kit See your dealer Wear strips are designed for a spec...

Page 67: ...ke Lock Brake Lever Brake System 67 68 111 Throttle Lever 65 81 Throttle Safety Switch 65 80 83 Auxiliary Shut Off Switch Engine Stop Switch 71 83 Ignition Switch 71 83 Taillight Brakelight Headlight 71 Coolant Level 106 Gearcase Oil Level 100 Engine Oil Level 92 Foam Oil Breather Element 97 Suspension Mounting Bolts 70 Skags Wear Bars 63 127 Ski Saddle and Spindle Bolts 70 Hood Straps Latches 66 ...

Page 68: ...he primary controls of your snowmobile Always make sure both are functioning properly Squeeze the throttle lever to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced i...

Page 69: ... place before operating the snowmobile n Steering System WARNING Ice and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice an...

Page 70: ... hydraulic system Refer to the brake bleeding information on page 113 Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 112 Check for the presence of air in the fluid system See page 113 for more information or see your dealer for service WARNING Continued use of spongy brakes may cause a complete loss of brakes which co...

Page 71: ...ove freely into place Do not force the lock or it may break The park brake light on the gauge will light up if the park brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the park brake light does not come on when the park brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake leve...

Page 72: ...e vehicle Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track dama...

Page 73: ...eck the following items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 123 Rear idler adjusting bolt locknuts Tightness Torque arm bolts Tightness Carrier and bogie wheel bolts Tightness Front torque arm limiter strap Condition Rail slide Condition 124 Track Tension 122 All rear suspension components Lubrication 98 Ski...

Page 74: ...ke sure the engine stops when the ignition switch is turned to OFF n Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating n Mirror Adjustment If equipped adjust your mirrors so they can be used to their full advantage n Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe d...

Page 75: ...el before operating a snowmobile that has tipped over or rolled over NOTE In the event of a tip over or rollover the engine will stop To restart the engine turn the key to the OFF position then restart WARNING Operating a snowmobile with accident damage can result in serious injury or death Do not operate the snowmobile if vehicle components have been damaged in a collision or tip over Have the sn...

Page 76: ...ames or sparks in or near the area where refueling is performed or where gasoline is stored S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of conscious ness or death in a short time WARNING The engine exhaust from this produ...

Page 77: ...ll throttle or high speeds for extended periods during the break in period Use of non recommended oil may cause serious engine damage Always use the recommended oil for your Polaris snowmobile 1 Fill the fuel tank with the recommended fuel See page 79 2 Check the oil level in the oil tank See page 92 Add oil if necessary to maintain at the recommended level 3 Drive slowly at first Vary the throttl...

Page 78: ...ting the Engine beginning on page 65 Do not depress the throttle until the engine starts 1 Turn the key to the ON position 2 Pull the engine stop switch up to the RUN position CAUTION To avoid injury and or engine damage do not operate the electric starter while the engine is running 3 Turn the key to START to crank the engine Release the key to the ON position when the engine starts 4 Repeat the ...

Page 79: ...the engine including scarves gloves jackets and clothing straps and hooks NOTE If a car or truck battery will be used to jump start the snowmobile turn the engine off A running engine will put out too much electrical current for the snowmobile battery NOTE Never attempt to jump start a discharged battery that is frozen 1 Always wear eye protection when jump starting your vehicle 2 Keep bystanders ...

Page 80: ...12 Make sure that the engine stop switch is in the UP position 13 Attempt to start the vehicle 14 If the engine does not turn over crank over wait 30 to 60 seconds and attempt to start the engine again If the engine does not start wait another 1 to 2 minutes and attempt to start the engine again 15 If the engine still does not start try adjusting the clips on the jumper cable ends to ensure that t...

Page 81: ...ry or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up of the engine drive train and track 1 Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper The track should be approximately 4 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptl...

Page 82: ...aces when handling fuel Fuel Level The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1 8th tank There will be approximately one gallon of fuel remaining Refuel as soon as possible Do not allow the snowmobile to run out of fuel Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl based fuel system deicer Add o...

Page 83: ...rottle safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a throttle system malfunction immediately push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer Test the throttle safety switch system daily before operation 1 Sit on the seat 2 Star...

Page 84: ...ngine doesn t start take the snowmobile to an authorized Polaris dealer for service NOTE Excessive freeplay in the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the snowmobile to an authorized Polaris dealer for service If an emergency exists and it s necessary to start the engine the throttle safety switch and engine stop switch m...

Page 85: ...e and while backing S Avoid sharp turns S Apply throttle slowly Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your snowmobile is clear 3 Push the yellow reverse button on the left hand control for one second then release NOTE A reverse light on the instrument panel will indicate that the snowmobile is in reverse 4 Apply the throttle slowly to make s...

Page 86: ...emergency See page 80 for more information about the engine stop switch and throttle safety switch SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Engine Stop Switch Interrupts ignition circuit All Throttle Safety Switch Interrupts ignition circuit All ...

Page 87: ...e towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in the towed object Braking distances increase when towing loads Slow down to maintain control of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach t...

Page 88: ... should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 The emission control system designation per SAE J1930 is MFI If you...

Page 89: ...the manual You must inspect the air intake system on your snowmobile prior to each use including the airbox foam filter and hood foam filters and clean these components as necessary Polaris considers the specified maintenance for the spark plugs oil changes air intake system and exhaust valves to be critical emission related maintenance The specified maintenance for the fuel filter is recommended ...

Page 90: ...g the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to service or make adjustments to your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfortable...

Page 91: ...e see your dealer for service D Brake Lever 67 Check lever travel and lever feel D Coolant 106 Inspect level add as needed D Brake fluid 112 Inspect fluid level add as needed D CHANGE EVERY 2 YEARS Hood Latches 66 Secure properly replace if damaged D Seat Latches 65 Secure properly replace if damaged D Rail Slide 124 Inspect for wear or damage replace when worn D Foam Oil Breather Element 97 Check...

Page 92: ...dlebars Verify alignment adjust as needed D D D Drive Chain 110 Verify tension adjust as needed EVERY Rear Track Shock M 10 Inspect covers and caps for wear or damage replace as needed EVERY Gearcase Oil 100 Check at 500 mi 800 km change every 1000 mi 1600 km D EVERY 1000 1600 Rear Suspension 98 Lubricate pivot shafts more often in wet snow conditions D D Bearings 131 Lubricate drive shaft and jac...

Page 93: ...outing replace as needed D D Brake Pads Disc 111 Inspect replace if worn or damaged D D Fuel Vent Lines 103 Inspect replace if worn or damaged D D Ski Toe 126 Verify alignment see your dealer for adjustments D D Cooling Fins Shroud Inspect and clean D D Valve Lash See your dealer FS Specifications Intake 0 08 0 15 mm Exhaust 0 15 0 20 mm FST Specifications Intake 0 08 0 15 mm Exhaust 0 18 0 23 mm ...

Page 94: ... 0W50 oil for this engine PS 4 has been specially formulated for use in Polaris 4 cycle snowmobile engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection Oil may need to be changed more frequently if Polaris oil is not used Always use 0W50 oil Follow the manufacturer s recommendations for ambient temperature op...

Page 95: ...owed precisely Always check the oil with the snowmobile positioned on a level surface Always check the oil when the coolant temperature is within the specified range 1 Position the vehicle on a level surface 2 If the engine is cold start the engine and allow it to idle until the engine coolant temperature reaches the specified range Proceed to step 4 3 If the engine has been running stop the engin...

Page 96: ...nges at specified coolant temperature B Safe operating range 8 Maintain the oil level in the safe operating range B between the upper and lower marks on the dipstick If the level is low add the recommended oil in small increments about 2 ounces 60 ml and recheck the level If the level is high remove 2 ounces 60 ml and recheck the level CAUTION Do not overfill the oil tank Engine damage may occur A...

Page 97: ...erature is between 145 and 160 degrees F 63 71 degrees C If necessary start the engine and allow it to idle until the coolant temperature is within the specified range 3 Turn the engine off CAUTION Hot oil and a hot exhaust system and engine can cause serious burns Do not allow hot oil or hot components to contact skin 4 Open the hood and remove the left side panel NOTE Clamp orientation is critic...

Page 98: ...se clamp securely but do not over tighten 16 To prevent oil spillage wait 3 to 5 minutes to allow any oil in the oil filter cap to drain out before removing it While waiting remove the foam oil breather element from the airbox See page 97 17 Inspect the foam element Clean it with soap and water and let it dry Reinstall it or install a new element if the existing element is damaged or degraded and ...

Page 99: ...B Safe operating range 25 Add additional oil to bring the level to the oil change fill mark A See the chart for approximate amounts to add at this step DO NOT OVERFILL MODEL OIL TO ADD AT STEP 25 Ounces Milliliters FS 4 to 16 118 to 473 FST 24 to 32 710 to 946 NOTE Check the oil level often during the fill procedure to avoid overfilling If the filling and checking procedure is not completed within...

Page 100: ...ommended The foam oil breather element is located inside the airbox A FS foam element B FST foam element 1 Open the hood 2 Release the airbox cover retaining clips and remove the cover 3 Remove the foam breather element 4 Wash the foam element in soapy water then rinse thoroughly and let dry NOTE If soap and water are not readily available remove as much liquid as possible by pressing the foam ele...

Page 101: ...cate liberally as shown Front Suspension The front suspension and steering components do not require lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 88 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of ...

Page 102: ...L L L L 99 MAINTENANCE Lubrication M 10 136 Rear Suspension Switchback Rear Suspension L L L L L ...

Page 103: ... numbers of Polaris products The dipstick A is located on the lower front side of the gearcase Maintain the oil level in the safe operating range B between the upper and lower marks on the dipstick Oil Check 1 Position the vehicle on a level surface 2 Remove the dipstick and wipe it dry with a clean cloth Reinstall the dipstick 3 Remove the dipstick and view the oil level 4 Add the recommended oil...

Page 104: ... the foam oil breather element See page 97 1 Position the vehicle on a level surface 2 Remove the drain plug and drain the oil into a drain pan Allow the oil to drain completely NOTE The sealing surfaces on the drain plug and the gearcase should be clean and free of burrs nicks or scratches 3 Reinstall the drain plug Torque to 6 10 ft lbs 8 13 Nm 4 Remove the dipstick 5 Add 9 oz 266 ml of the reco...

Page 105: ...up and the vehicle has been driven at higher speeds If a plug is fouled replace the plug using the tools provided in the tool kit WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection Normal Spark Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or ...

Page 106: ...Polaris dealer Do not attempt to service the fuel pump Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 88 Fuel Lines Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal deterioration from weather and fuel compounds m...

Page 107: ...belt rotates 1 4 turn 90 degrees or more as shown tighten the belt or install a new belt Air Filter FST Inspect the air filter for oil and dirt accumulation at the intervals outlined in the Periodic Maintenance Table beginning on page 88 1 Open the air box 2 Remove the air filter 3 Shake or pat the filter to clean it or install a new filter Do not attempt to clean the filter with liquids Foam Oil ...

Page 108: ...ever perform this procedure with the engine running 1 Allow the engine and exhaust system to cool completely 2 Open the hood 3 Inspect the muffler and pipes for cracks or damage Check for weak or missing retaining springs or damper support grommets 4 Replace any damaged or missing components 5 Clean the plastic surfaces next to the muffler with aerosol Carburetor and Throttle Body Cleaner NOTE See...

Page 109: ...eposits and may react adversely with the metals in the engine and cooling system Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part n Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are S Coolant bottle or overflow tank S ...

Page 110: ... light is on Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine the system should be completely drained every two years and a fresh mixture of antifreeze and distilled water should be added Have your Polaris dealer perform this service Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Maintenance Table beg...

Page 111: ... bleed the cooling system or remove the pressure cap when the engine is warm or hot 3 Open the hood 4 Remove the coolant pressure cap A carefully 5 Slowly pour coolant into the filler neck B until the coolant level reaches the bleed return hole C on the inside of the filler neck Leave the pressure cap off 6 With the cap off start the engine and allow it to idle 7 With the engine idling observe the...

Page 112: ... and 9 Make sure steps 8 and 9 are followed precisely during the entire bleed procedure 11 While the engine temperature is rising allow the engine to idle until the temperature reaches approximately 220 F 104 C Do not stop the engine at this step 12 Feel the coolers at the rear of the snowmobile rear cooler de icers grippers as equipped These components should be warm to the touch indicating the t...

Page 113: ...to move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut A 3 Finger tighten the adjuster bolt B until it can no longer be adjusted by hand then back off 1 4 turn 4 Tighten the jam nut while holding the adjuster bolt Torque to 18 23 ft lbs 24 31 Nm 5 Release the brake lever lock ...

Page 114: ...ly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 1 5mm Brake Components A Brake Disc B Bleed Screw C Brake Line D Brake Caliper E Brake Pad Material Replace when thickness is less than 1 16 1 5mm Ex...

Page 115: ...of dirt and debris The vent slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function CAUTION Brake fluid will damage decals paint and some plastics Always wipe up spills immediately Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid See page 133 for the part numbers ...

Page 116: ... 2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 6 8 cm below the lip of the reservoir opening Reinstall the gasket and cover 3 Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve an...

Page 117: ...ched to the bulb C withdraw the bulb from the housing 5 Grasp the bulb by its metal base and carefully separate the bulb from the harness Installing Halogen Bulbs 1 Hold the bulb by its metal base and install it into the wire harness 2 Insert the bulb into the housing 3 Connect the spring to the housing 4 Carefully flip the spring back into the housing placing it around the wire harness 5 Reinstal...

Page 118: ...haust sensor EX SENSOR GAUGE 20A Gauge GAUGE 20A REVERSE SHIFT Reverse shift REVERSE SHIFT Accessory projector beam relay Diagnostic plug IGNITION 20A Ignition relay power EFI RELAY Cam phase sensor RELAY ECU hold on power Reverse limit switch Forward limit switch EFI Start relay coil EFI 20A Chassis relay coil Ignition relay coil Fuel pump relay coil Fan relay coil Fuel pump relay power PTO injec...

Page 119: ...n the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Clutch Alignment and Offset Clutch alignment offset A is important for maintaining optimum performance See your Owner s Manual Supplement for the recommended offset between the drive and driven clutches with the belt removed Belt width and length must match the ce...

Page 120: ...warm it to room temperature Reinstall it before starting the snowmobile n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge on the belt A and apply downward pressure while measuring at point B This measurement should be 1 1 4 3 2 cm Drive Belt Adjustment TEAM Clutch 1 Loosen the 7 16 jam nut on the belt width adjuster ...

Page 121: ...on NOTE For easier accessibility make sure the clutch tool access hole is visible between the 11 00 and 2 00 positions of the clutch sheave 2 Turn the ignition key off Wait for the engine to come to a complete stop 3 Lock the parking brake 4 Open the hood 5 Remove the left side panel 6 Locate the L wrench in the tool kit Install the wrench into the open threaded access hole in the outer sheave of ...

Page 122: ...he same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt removal procedures 2 Rotate the L wrench counter clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the wrench and store it in the tool kit 4 Reinstall the side panel 5 Close and secure the hood ...

Page 123: ...e recommended for your model Track Inspection WARNING Broken track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and support the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track ...

Page 124: ... rail requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear NOTE Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty CAUTION High speed use on hard packed surfaces is not recomme...

Page 125: ...surement C Switchback 10 lbs 4 54 kg 16 ahead of rear idler shaft 3 8 1 2 1 1 3 cm M 10 128 10 lbs 4 54 kg 16 ahead of rear idler shaft 7 8 1 1 8 2 2 2 9 cm M 10 136 10 lbs 4 54 kg 16 ahead of rear idler shaft 7 8 1 1 8 2 2 2 9 cm NOTE Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the snowmobile and safely support it off th...

Page 126: ...as necessary to provide equal adjustment on both sides of the track 8 Repeat the measurement on the other side of the track NOTE Check more frequently when the snowmobile is new 9 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 10 Check track alignment see page 124 and adjust as necessary 11 Tighten the locknuts A 12 Tighten t...

Page 127: ...ect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track runs to the left loosen left locknut and tighten the left adjusting bolt If the track runs to the right loosen right locknut and tighten the right adjusting bolt 4 After adjustments are complete tighten locknuts and torque idler shaft bolts to 35 ft lbs 47 5 Nm 5 Repeat steps ...

Page 128: ...125 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary ...

Page 129: ...See your Polaris dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement between the skis at point X should be 1 8 to 1 4 greater than the measurement at point Y NOTE If the skis are misaligned we recommend that your dealer correct the alignment since...

Page 130: ...ed snow or ice Check skags before each use of the snowmobile to ensure positive steering characteristics Skags must be replaced when worn to half their original diameter NOTE Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement NOTE Some models are equipped with single skags Other models are equipped with dual skags 1 Raise and support the front of the snowmobi...

Page 131: ...ery cable last 5 Lift the battery out of the vehicle Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 129 before installing the battery 1 Ensure that th...

Page 132: ...cted during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully cha...

Page 133: ... explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Charge Voltage Action Charge Time Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts ...

Page 134: ...paint The snowmobile should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components Battery Maintenance Remove the battery and recharge it as outlined on page 129 Store the battery in a cool dry place Controls and Linkage Lubricate all bushings and cables at the intervals outlin...

Page 135: ...ecured away from sharp edges steering linkage moving parts and hot exhaust parts Track and Suspension Moderate track tension should be maintained during summer storage The snowmobile should be supported off the ground to allow the track to hang freely See illustration Transporting the Snowmobile Whenever the snowmobile is transported 1 Be sure the fuel cap and oil cap are installed correctly 2 Alw...

Page 136: ...ants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogelt Coolant 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT4 Brake Fluid 12 oz 2872893 Engine Degr...

Page 137: ... to the ground Jammed or broken chaincase sprocket or chain See your dealer Mechanical failure See your dealer Engine Doesn t Turn Over Possible Cause Solution Low battery voltage Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine stop switch is off Lift the stop switch to the ON position ...

Page 138: ...ter Replace the filter Low battery voltage Recharge the battery to 12 8 VDC Poor engine compression See your dealer Mechanical failure See your dealer Engine Backfires Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Mec...

Page 139: ...clean or replace Air flow through intake is too warm FST only Boost is limited until cooler air flows through the intake Engine management system failure See your dealer Engine overheating See the Engine Overheating trouble shooting section Fuel in crankcase See your dealer Drive clutch binding See your dealer Incorrect clutching See your dealer Driven clutch malfunction See your dealer Worn drive...

Page 140: ...orrect belt Replace with the recommended belt Incorrect clutch alignment See your dealer Broken or loose engine mount See your dealer Drive System Noise Possible Cause Solution Broken drive clutch components See your dealer Bearing failure chaincase jackshaft or front drive shaft See your dealer Flat spots on drive belt surface Inspect and replace as needed Loose drive chain Inspect and adjust or ...

Page 141: ...torsion spring blocks or install optional torsion springs to achieve correct sag dimensions S Move limiter strap on front torque arm to low position see page 51 Front end pushes S Check for worn skags S Check for binding front suspension shafts and steering com ponents grease all pivot points elevate front of machine S Verify sag dimension see page 50 Adjust torsion spring blocks or install option...

Page 142: ...aler S Check track tension see page 122 Front end pushes S Check for worn skags S Check for binding suspension shafts and grease all pivot points S Shorten front limiter strap S Install single skags see your dealer Steering is heavy S Check skags and skis for damage S Check ski alignment see page 126 S Make sure spindles and all steering components turn freely S Verify sag dimension see page 54 Ad...

Page 143: ...rack and tunnel S Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine performance S Check for fouled plugs or water ice or dirt in the gas tank or fuel line Loading machines onto trailers S Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to dr...

Page 144: ...n 3 Dealer name 7 Previous correspondence 4 Date of purchase Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris Customer Service United States 1 763 417 8650 Canada 1 204 925 7100 Polaris Anti Theft System The Polaris anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles ...

Page 145: ... not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for purposes other than for which it was manufactured The warranty does not cover any damages that oc cur during tra...

Page 146: ...ust present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at Polar...

Page 147: ...rcuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark...

Page 148: ...utomatic with no additional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes S Damage due to accident fire explosion theft or other causes beyond Polaris control S Damage caused by the failure of other co...

Page 149: ...take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of t...

Page 150: ...e covered by this warranty This includes compo nents whose failure increases the snowmobile engine s emissions To the extent they are present on your snowmobile engine this includes electronic controls fuel injection com ponents exhaust gas recirculation system components and aftertreatment system compo nents Replacing or repairing other components not covered by this warranty is the responsibilit...

Page 151: ...uses beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris can deny an emissions warranty claim if any specified critical emissions re lated maintenance is not performed Performance of other scheduled maintenance is strong ly recommended but is not necessary to keep the emissions related warranty valid Any qualified r...

Page 152: ...er each time your snowmobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 1500 mi 2400 km ...

Page 153: ...150 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 154: ...151 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 155: ...Controls and Linkage 131 Coolant 106 Coolant Level 106 Cooling System 106 109 D Daily Storage 84 Deep Snow 20 Detonation Elimination Technology 36 Digital Display Identification 37 Disabled Operators 12 Drive Belt 19 117 118 Adjustment 117 Condition 117 Deflection 117 Installation 119 Removal 118 Drive Chain Tension 110 Driver Awareness 15 Driveshaft Bearing 98 Driving Downhill 17 Driving in Hilly...

Page 156: ... Digital Display Programs 39 43 MFD Settings 38 Mirror Adjustment 71 O Oil Breather Element 97 Oil Change 94 96 Oil Level Check 92 93 Oil Engine 91 96 Operating in Deep Snow 20 Operation 26 73 84 Operator Safety 8 22 P Passenger 24 Passenger Grab Handle Adjustment 61 Passenger Seat 29 PERC 82 Polaris Products 133 Pre Ride Checklist 64 Pre Ride Inspections 64 72 Pressure Cap 23 R Radiator Compartme...

Page 157: ...nsion Rear M10 54 59 Symbols 8 T Taillight Brakelight Replacement 114 Throttle Cable 98 Throttle Lever 81 Throttle Safety Switch 80 Tip Over Inspections 72 Tool Kit 87 Torsion Spring Tension 51 Towing 84 Track 24 132 Track Alignment 124 Track Inspection 120 Track Inspection Pre Ride 69 Track Lubrication 121 Track Replacement 120 Track Safety 10 Track Tension 122 123 Track Tension Data 122 Track Wa...

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Polaris FS Classic, Owner'S Manual

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