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Polaris FS IQ TOURING 2008, Owner'S Manual

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Polaris FS IQ TOURING 2008 Owner'S Manual Download Page 138

135

MAINTENANCE

Clutch System

n

Drive Belt Condition

Periodically check the condition and tension of the drive belt, and 

always carry a spare. Inspect the belt for signs of excessive wear: frayed 

edges, missing cogs, cracks and excessive looseness. Replace the belt if 

any of these conditions exist. See Drive Belt Troubleshooting on page 

158.
For improved drive-away during extremely cold temperatures, remove 

the belt and 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 

and apply downward pressure 

while measuring at point A. 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.
2. Using a 1/8" Allen wrench, adjust the threaded set screw as needed.

NOTE:

Turn the set screw in (clockwise) to increase the distance between the 

sheaves and out (counterclockwise) to decrease the distance.

3. Tighten the jam nut.

Straight 

Edge

Measure

A

Summary of Contents for FS IQ TOURING 2008

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Page 3: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 4: ...r 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 is i...

Page 5: ...in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation 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 54 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 74 This section explains procedures that must be performed before riding Operation 83 This section explains proper engine break in operation of features and general operating procedures Maintenance 97 This section...

Page 7: ...4 ...

Page 8: ... 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 and preserve your right to ride by joining your local trail riding clubs When teaching inexperienced operators to ride set up a predetermined course for practice Ma...

Page 9: ...of 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 ...

Page 10: ...aris 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 _____________________________________________________________ lower right side of the tunnel Engine Serial Number on valve cover _______________________________________ Key Number ____________________________...

Page 11: ...rt 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 ...

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: ...k its operation WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the snowmobile up or stand 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 ser vice and alignment pr...

Page 14: ... must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cel lular telephone Always carry the owner s manual on your snowmobile For added pro tection purchase an...

Page 15: ... will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be prep...

Page 16: ...ld never be operated with more than two people on board When traveling with a passenger it s the driver s responsibility to operate the snowmobile safely Slow down Control becomes more difficult with two people on board More space is required to make turns and longer distances are necessary for stopping WARNING Control becomes more difficult with two people on board More space is required to make ...

Page 17: ... rear of the machine may reduce your ability to steer Do not exceed carrier and rack weight limits and do not allow a passenger to sit on the seat back or the cargo carrier WARNING Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Do not allow disabled persons to operate this vehicle ...

Page 18: ...wmobile will travel about 120 feet 36 m If your speed is 60 MPH 96 km h your snowmobile will travel about 180 feet 55 m in two seconds Traveling at night requires extra caution Check headlight and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your snowmobile to a stop in the distance illu minated by the headlight WARNING High speed driving es...

Page 19: ...o difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your snowmobile will drown out the sound 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 ma...

Page 20: ...snow is connected You may be riding on a 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 ava lanche advisory to get current weather and snow stability information Fo...

Page 21: ...e 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 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 WARNING When driving on long downhill stretches pump t...

Page 22: ...revent it from rolling back down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill side of the snowmobile pull the rear of the snowmobile around and point the front end and skis downhill Remount the snowmo bile restart the engine release the parking brake and descend the hill carefully WARNING Never attempt an abrupt change of direction when operating on...

Page 23: ...eeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially 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 24: ...wmobile becomes stuck in snow clear the running board area of snow then step down the snow in front of the snowmobile so that when the throttle is opened the snowmobile will be able to climb up and over the snow WARNING Inadequate cooling and lubrication will lead to overheating of the slide rail and track causing premature wear damage and failure which can result in serious injury Reduce speeds a...

Page 25: ...l as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide pro tection under normal riding conditions Your snowm...

Page 26: ...6 93 50 26 19 12 4 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 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 ...

Page 27: ... 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 WARNING 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 28: ...iles designed for an operator and one passenger have a warning decal on the left console For more information on operating with a passenger see page 13 WARNING This vehicle is designed for operator and ONE passenger only Track Warning WARNING Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death No Passenger Warning or...

Page 29: ...injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Machine stopped and engine at idle push yellow button on LH con trol to reverse Flashing light on dash indicates reverse operation Push button again to return to fo...

Page 30: ...s wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements 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 When operating on hard packed snow ice or when crossi...

Page 31: ... snowmobile 4 Hood 5 Headlight 6 Windshield 7 Storage Compartment or Cargo Bag 8 Operator Seat 9 Passenger Seat 10 Backrest 11 Passenger Grab Handle 12 Grab Handle Heater Switch 13 Taillights 14 Rear Bumper 15 Snow Flap 16 Track 17 Suspension 3 4 5 6 7 2 1 8 9 10 12 13 14 15 16 17 11 ...

Page 32: ... Handlebar Grip Warmer Switch 8 Thumbwarmer Switch 9 Electronic Reverse Button 10 MFD Control 11 Headlight Dimmer Switch 12 Parking Brake Lock 13 Brake Lever 14 Engine Stop Switch 15 Throttle Control 16 M 10 ACE Suspension Adjustment Switch Cruiser 17 Ignition Switch 17 1 13 14 15 12 7 8 9 10 11 16 3 1 6 4 5 ...

Page 33: ...osen the lower adjustment knobs to move the backrest for ward for operator use or rear ward for passenger use 3 Always tighten the knobs securely after adjusting M 10 ACE Suspension Adjustment Switch A switch on the console above the ignition switch allows you to adjust the M 10 ACE suspension with the MFD control switch See page 69 for instructions Operator Passenger Raise Lower ACE Suspension Ad...

Page 34: ...provide open storage for transporting larger items The maximum weight capacity for the cargo area is 30 lbs 14 kg Always secure cargo before operating Do not exceed the weight limit Do not allow a passenger to sit on the seat back or the cargo area 1 Push down on the seat latch lever which is located at the lower rear of the passenger seat 2 Lift up the seat and remove it from the chassis 3 Revers...

Page 35: ...erating Do not exceed the carrier weight limit Do not allow a passenger to sit on the seat back or the cargo area 1 Adjust the backrest to the for ward operator position See page 30 2 Release the trunk cover latch 3 Lift the trunk assembly upward and rearward to remove it 4 Install the passenger seat securely 5 Install the cargo bag and secure the straps to the cargo carrier sides 6 Adjust the bac...

Page 36: ...f equipped use the outlet to power a global positioning sensor GPS heated helmet shield utility light cell phone or other accessories The 12 volt DC outlet is installed in the recoil pocket next to the right hood hold down If you install an accessory outlet on your model always install it in the recoil pocket The fuel filter is installed in the upper console area Do not install an outlet on the up...

Page 37: ... adjustability Removing this lockout and using RIDER SELECT posi tion 6 or 7 will result in the handlebars and brake lever contacting other com ponents and interfering with steering and braking This could lead to loss of control resulting in serious injury or death Always be sure that the handle bars and brake lever do not contact any other snowmobile components at any steering position AND at any...

Page 38: ...rail Riding Boondocking Deep Snow Riding Rider weight is centered on the snowmo bile providing balance comfort and con trol for both novice and experienced riders This is the recommended position for most riding situations 6 7 Snowcross Steep Hill Climbing Only Rider weight is ahead of the center of the snowmobile adding weight to the skis and making the snowmobile heavier in the front These posit...

Page 39: ...Do not lubricate the RIDER SELECT mechanism Doing so could cause loss of control and result in serious injury or death The RIDER SELECT mecha nism 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 This could...

Page 40: ... 2 Check battery voltage on the gauge and install a new battery if volt age is low see page 52 3 Verify that engine temperature is within the recommended operating range See the Turbo Boost chart on page 38 A flashing MIL may also 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 ...

Page 41: ...Reverse is selected speed sensor error Reverse 5300 Engine will mis fire at higher engine speed Defective rollover switch speed sensor error Rollover 6000 Throttle stuck throttle lever depressed speed sensor error Throttle stuck throttle safety switch high 5450 Throttle stuck throttle lever at idle position Throttle stuck throttle safety switch low 2400 Maximum vehicle speed speed sensor error Max...

Page 42: ...tutter If you do not notice the flashing indicator on the MFD or do not suffi ciently cool the snowmobile the engine will misfire to alert you to look at the MFD and take action Again driving the snowmobile into soft snow or packing snow onto the heat exchangers should cool the engine 3 The engine will stop If the engine reaches an extreme temperature where damage becomes possible the system will ...

Page 43: ...fely 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 Fail Safe The knock sensor includes a sensor fail safe system to prevent the engine from damage if th...

Page 44: ...if equipped Service Interval 2 Electrical System Voltage Level all models and M 10 ACE Suspension Adjustment RIDE Cruiser only 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 Le...

Page 45: ...ill display either standard or metric units of measurement While viewing a screen that displays measurements MPH km h or temperatures press and hold the MODE switch until the unit of mea surement changes about 10 seconds ACE Suspension Adjustment IQ Cruiser The MFD control switch also operates the M 10 ACE rear suspension adjustment When the blue ACE adjustment switch on the console is in the GAUG...

Page 46: ... display the tachometer option 1 If the analog is set to show the tachometer the digital screen will show the speedometer option 2 To change viewing preferences press and hold the MODE button for three seconds When the button is released the new setting becomes active and screen colors change See table below Option Analog Display Digital Display Analog Screen Digital Screen 1 Speed RPM Blue MPH Bl...

Page 47: ...er whichever is selected See page 43 Press and release the SET button to cycle through the following screens odometer trip 1 odometer trip 2 odometer fuel trip odometer if fuel is low and clock if equipped Use the following procedures to make changes to these screens Odometer Setting The odometer records the vehicle s total distance traveled since manufacture The odometer cannot be reset Trip Sett...

Page 48: ...pped with an electronic fuel gauge The fuel symbol and the last fuel bar on the MFD gauge if equipped will blink when the fuel level reaches 1 8 of a tank The Trip F odometer records distance traveled and the fuel symbol continues to blink until enough fuel is added to raise the level above 1 4 of a tank The Trip F odometer will automatically reset to zero after refueling ...

Page 49: ...onds 4 When the hour starts flashing press the SET switch once to advance one hour NOTE Press and hold the SET button to advance the hours quickly 5 Press and release the MODE button to save the hour The minutes will begin flashing 6 Set the minutes in the same manner 7 When finished press and release the MODE button to save the new setting NOTE If the MODE button is not pressed within ten seconds...

Page 50: ...llowing screens hour meter engine temperature air temperature available as an acces sory altimeter available as an accessory and turbo boost if equipped Hour Meter The hour meter records the total hours of engine operation since manufacture This meter cannot be reset Engine Temperature A thermometer measures water temperature giving an indication of engine temperature Air Temperature if equipped T...

Page 51: ...ickly by 100 foot 30 m increments 5 Adjust the altitude display to within 50 ft 15 m of current altitude NOTE The gauge reads barometric pressure and allows the rider to compen sate 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 h...

Page 52: ...Maximum RPM The gauge automatically logs the maximum speed and engine RPM even if the history program is not active in the display 1 Enter the History Program 2 Press and release the SET button until one of the two screens is active NOTE The MPH and RPM values are both reset at the same time Reset the val ues before each run to obtain accurate readings 3 Press and hold the SET button for three sec...

Page 53: ...odometer area and ENG will flash in the icon area for five seconds each time the engine is started until the service reminder is reset Use the following procedures to reset the reminder To reset the reminder at the existing interval 1 Enter the History Program 2 Press and release the SET button until the service interval screen is active 3 Press and hold the SET button for ten seconds continuing t...

Page 54: ...active 3 Press and hold the SET button for five seconds until the hours begin to flash Immediately release the button 4 Press the button again up to five times to advance the reminder in 50 hour increments NOTE The maximum interval is 250 hours 5 Press and release the MODE button to save the new settings To disable the service interval reminder 1 Press the SET button once after reaching 250 hours ...

Page 55: ...le from your dealer 1 Remove the plenum from the under side of the hood 2 Locate the black battery compart ment It has a red wire and a brown wire with a white stripe It s located about three inches down the main harness from the point where the harness connects to the MFD 3 Cut the plastic cable tie from the outside of the compartment 4 Carefully cut the bottom of the compartment opposite the wir...

Page 56: ...ake sure the taped seam of the compartment faces the downward side of the wire harness 9 Install a cable tie to secure the compartment to the wire harness in the same location where the previous cable 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 clot...

Page 57: ... starting with factory settings and then customizing 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 condi tions 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 Op...

Page 58: ... most riders and conditions Please see your Polaris dealer for assistance before attempt ing to adjust preload Increasing the spring preload too much may adversely affect the han dling of the snowmobile and the performance of the rear suspension Decreasing the spring preload too much may allow the lower spring retainer to fall off ...

Page 59: ...gen pressure The upper chamber adjusts the main spring rate The lower chamber adjusts preload See your Polaris dealer for more information WARNING Changing shock valving requires special tools and a sound knowledge of mechanical theory tool use and shop procedures to perform the work safely and correctly Shocks contain high pressure nitrogen gas Use extreme cau tion when handling high pressure ser...

Page 60: ...e your dealer Suspension Performance Tips 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 In deep snow a new rail slide will offer improved performance o...

Page 61: ...eated measure the distance between the ground and the rear bumper at the exact location used for measure ment X This is measurement Y To determine sag commonly referred to as ride in subtract measure ment Y from X sag X Y If the measured sag is incorrect adjust the FRA position and or rear torsion spring preload NOTE This is only an initial setup and final spring preload may vary based on rider pr...

Page 62: ... position cam using the engine spark plug tool Adjustment is easiest when the cam is rotated from low to medium and then to high Rotating directly from low to high will require significantly more effort Different rate torsion springs are available if a firmer ride is desired See your dealer for more information Soft Medium Firm ...

Page 63: ...uspension coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amount of indepen dence between the movement of the front torque arm and the rear torque arm When hitting a bump the front torque arm starts to compress The FRSS links that movement to the rear torque ar...

Page 64: ...usting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performance An adjustment dot is located on the RRSS This dot is on the longest end of the scissor stop Rear Rear Scissor Stop RRSS Attributes Moving the RRSS to a higher position will have the following effects on the suspension Reduced ...

Page 65: ...est for most trail riding conditions To decrease weight transfer under acceleration for improved corner ing rotate the RRSS to a higher position To increase weight transfer or ski lift during acceleration rotate the RRSS to a lower position NOTE Your dealer can help you with initial setup and additional setup instructions to help you achieve your optimum ride A scissor stop tool is also available ...

Page 66: ...ease take the time to read and understand all the possible adjustments available with this suspen sion Static Sag and Ride Height Settings Static sag describes the difference in height of the rear bumper from the suspension s fully extended 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 com...

Page 67: ... to set in the suspension While the rider remains seated measure the distance from the ground to the top of the bumper dimension Y and record it 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 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 6...

Page 68: ...ST effect on the rear suspension performance To adjust the FRA 1 Refer to the initial set up reference chart see page 68 to determine the desired FRA position 2 To adjust see page 69 NOTE When the M 10 suspension is new it will take from 25 to 200 miles 40 300 km to properly break in the springs and shocks at which time the suspension will be softer and may require FRA re adjustment ...

Page 69: ...to adjust the preload and change the sag See your Polaris dealer for assistance NOTE Whenever ordering any of the retainers listed in the chart always order the retainer insert as well The insert is not removable once installed so a new insert is needed when installing a new retainer OPTIONAL RETAINERS Retainer Insert Part Number Retainer Part Number Preload Sag 5436109 5135077 standard on M 10 12...

Page 70: ...fers comfort or con trol Lean toward the 4 setting for comfort and toward the 3 setting for aggressive riding 2 For full hole adjust ments 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 st...

Page 71: ...ont limiter strap at some point you will collapse the rear suspension arm which will affect SAG height and reduce rear suspension travel Initial M 10 Suspension Set up Chart These charts are a guideline to be used for initial suspension set ups Your set up may vary based on your desired riding style You may prefer an optional rear track middle spring retainer See page 66 M 10 136 Rider s Weight wi...

Page 72: ...and release the MODE button to increase the ACE set ting for a firmer ride 5 Press and release the SET button to decrease the ACE setting for a softer ride NOTE Each time the MODE or SET button is pressed the ACE suspension will adjust one position The RIDE display indicates the new position and the former position by flashing the bars between the two positions one bar for each level of adjustment...

Page 73: ... the adjuster block turn han dlebar 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 han dlebars 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 4 Torque the front bolts first then torqu...

Page 74: ...owmobile Use of unapproved parts and accessories may result in Non compliance with government industry requirements Voiding of warranty Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems NOTE Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service ...

Page 75: ...sed increased wear to the brake pads will result from increased braking Extended wear brake pad kits are avail able See your dealer CAUTION Always install wear strips before installing studs Failure to install wear strips may result in cooler or tunnel damage See page 73 Never add shims to the wear strip Track damage will result because of lack of clearance between upper carrier wheels and track U...

Page 76: ...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 77: ...Lock Brake Lever Brake System 77 78 129 Throttle Lever 75 Throttle Safety Switch 75 Auxiliary Shut Off Switch Engine Stop Switch 81 95 Ignition Switch 81 95 Taillight Brakelight Headlight 81 Coolant Level 123 Gearcase Oil Level 115 Engine Oil Level 104 Foam Oil Breather Element 112 Suspension Mounting Bolts 80 Skags Wear Bars 73 145 Ski Saddle and Spindle Bolts 80 Hood Straps Latches 76 Seat Latch...

Page 78: ...he 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 func tion smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately n Throttle Safety Switch Test the throttle safety switch system before the snowmobi...

Page 79: ...ce before operating the snowmo bile n Steering System 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 and snow build up that may be obstructing the steering linkage NOTE If your snowmobile is equipped with RIDER SELECT perform this check in both the full up and full dow...

Page 80: ...ulic system Refer to the brake bleeding infor mation on page 131 Brake Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 130 Check for the presence of air in the fluid system See page 131 for more information or see your dealer for service WARNING Continued use of spongy brakes may cause a complete loss of brakes which c...

Page 81: ... place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever t...

Page 82: ...ause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle Use of traction products such as studs increases the possibility of track dam age 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 lubrica...

Page 83: ...the follow ing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 141 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 142 Track Tension 140 All rear suspension components Lubrication 114 Ski r...

Page 84: ...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 advan tage n Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe dis...

Page 85: ... position then restart CAUTION Failure to check the oil after a tip over can result in serious engine damage Always check the oil level before operating a snowmobile that has tipped over or rolled over 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 86: ...es or sparks in or near the area where refueling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time WARNING The engine exhaust from this product cont...

Page 87: ...ntain at the recommended level 3 Drive slowly at first Vary the throttle positions Do not operate at sustained idle 4 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 74 5 During the break in period change both the oil and the filter at 500 miles or before seasonal storage whichever comes first CAUTION Excessive heat build up du...

Page 88: ... the engine starts Continue to apply just enough throttle to keep the engine running until it idles smoothly 4 Turn the key to START to crank the engine Release the key to the ON position when the engine starts 5 Repeat the cranking procedure as needed until the engine starts NOTE Always allow the engine to warm up to full operating temperature 150 F 65 C before shutting it down Avoid starting and...

Page 89: ...ile battery NOTE Never attempt to jump start a discharged battery that is frozen WARNING Improperly connecting or disconnecting jumper cables can result in an explo sion and cause serious injury or death When connecting jumper cables always connect the negative usually black cable last When removing jumper cables always disconnect the negative usually black cable first WARNING Loose fitting clothi...

Page 90: ... cable to the fuel system or fuel lines 8 Pull back the red plastic boot covering the positive terminal of the weak battery Connect one end of the positive jumper cable to the positive terminal of the weak battery 9 Connect the other end of the positive jumper cable to the positive terminal of the charged battery NOTE Make sure that the end of the negative cable by the weak battery is not contacti...

Page 91: ...sure that they have a good electrical connections Repeat step 14 16 If the engine still does not start remove the jumper cables as out lined in step 17 and transport the snowmobile to an authorized Polaris dealer for service 17 Carefully remove the jumper cables in this order A Remove the negative end of the jumper cable from the snowmobile chassis B Remove the negative end of the jumper cable fro...

Page 92: ... fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol Polaris also recommends the use of Carbon Clean Plus See page 151 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deic ers or w...

Page 93: ...nd it while warming up the track Do not use excessive throt tle during warm up or when the track is free hanging Be sure the rear sup port is stable WARNING Use of traction products such as studs ice growsers etc will increase the possibility of track damage and or failure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the sno...

Page 94: ...f the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revo lutions NOTE It will take longer to warm up the track sufficiently during colder out door temperatures 4 Release the throttle apply the brakes shut off the engine and lower the snowmobile to the ground 5 Grasp the skis by their front loops and move...

Page 95: ...ause vehi cle speed and engine speed to be limited This four stroke snowmobile has a self diagnostic check of the throttle safety switch The switch operation is checked through the engine con trol unit for correct operation If a defective switch is detected by the self diagnostics system the MIL will illuminate Take your snowmobile to an authorized Polaris dealer for diagnosis and repair if the MI...

Page 96: ...oesn 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 Turbo Noise Turbo models Under some conditions when the throttle lever is released the boost pressure dump valve will re...

Page 97: ...make sure the transmission is in reverse NOTE If the engine stops running the transmission will be in forward gear when it s restarted WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occur to the gearcase or transmission if shifting is attempted when the engine is operating above idle speed Shift to or from reverse on...

Page 98: ... off 3 Apply the throttle slowly to make sure the transmission is in for ward n Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 92 for more information about the engine stop switch SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Engine Stop Switch Interrupts ignit...

Page 99: ...ove the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting th...

Page 100: ...l 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 yo...

Page 101: ...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 speci fied maintenance for the fuel filter is recommended...

Page 102: ...become the responsibility of the regis tered owner If during 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 adjust ments to your snowmobile If you re not familiar with safe service or adjustment proc...

Page 103: ...ever feel O Coolant 123 Inspect level add as needed O Brake fluid 130 O CHANGE EVERY 2 YEARS Hood Latches 76 Secure properly replace if damaged O Seat Latches 75 O Rail Slide 142 Inspect for wear or damage replace when worn O Foam Oil Breather Element 112 Check pre ride clean or replace with each oil change Clean after tipping 3 times onto left side O O O O Front and Rear Sus pension and Steering ...

Page 104: ... Chain 128 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 115 Check at 500 mi 800 km change every 1000 mi 1600 km O EVERY 1000 1600 Rear Suspension 114 Lubricate pivot shafts more often in wet snow condi tions O O Bearings 113 149 Lubricate drive shaft and jackshaft bearings O O Throttle Cable 113 Lubricat...

Page 105: ...g replace as needed O O Brake Pads Disc 129 Inspect replace if worn or damaged O O Fuel Vent Lines 119 Inspect replace if worn or damaged O O Ski Toe 144 Verify alignment see your dealer for adjustments O O Cooling Fins Shroud Inspect and clean O O Valve Lash See your dealer FS Specifications Intake 0 08 0 15 mm Exhaust 0 15 0 20 mm FST Cruiser Specifications Intake 0 08 0 15 mm Exhaust 0 18 0 23 ...

Page 106: ...oil PS 4 or PS 4 Plus 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 PS 4 oil is not used Follow the manufacturer s recommendations for ambient tempera ture oper...

Page 107: ...mobile must be on a level surface and the engine coolant tem perature must be between 145 and 160 degrees F 63 71 degrees C NOTE Always check the oil level before operating a snowmobile that has tipped over CAUTION Severe engine damage may occur if procedures for checking the oil level are not followed precisely Always check the oil with the snowmobile positioned on a level surface Always check th...

Page 108: ...emperature is within the specified range for performing the oil check Allow the engine to cool if necessary When the coolant is within the specified range restart the engine and allow it to idle for no more than 20 seconds to circulate the oil back into the tank 4 Turn the engine off NOTE Check the oil level within three minutes before the coolant tem perature and oil level begin to drop 5 Remove ...

Page 109: ...e bottom of the safe operating range on the dip stick 9 If the level is high remove 2 ounces 60 ml and recheck the level 10 Recheck the oil level if oil was added or removed making sure the coolant temperature is within the specified range If necessary con tinue adding or removing oil until the level is in the safe operating range CAUTION Do not overfill the oil tank Engine damage may occur Always...

Page 110: ...level check procedure begin ning on page 104 4 If oil is not present add 1 2 quart 47 l of the recommended oil Reinstall the dipstick start the engine for no more than 5 seconds stop the engine and recheck for the presence of oil 5 If oil is present continue with the oil level check procedure begin ning on page 104 6 If oil is not present add another 1 2 quart 47 l of oil Reinstall the dipstick st...

Page 111: ...urn over the engine without start ing it You may also need an assistant to help with the oil change 1 Position the vehicle on a level surface 2 Make sure the engine coolant temperature 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 4 Open the hood and remove the le...

Page 112: ...from the fuse block 11 Reinstall the left side panel 12 Have an assistant use the ignition key to turn over the engine Crank the engine for 15 seconds 13 Wait 30 seconds to allow the starter motor to cool down 14 Repeat steps 12 and 13 four more times for a total of five cycles 15 Reconnect the oil return line to the oil tank Make sure the hose and clamp are properly seated Make sure the clamp is ...

Page 113: ... Reinstall the 20A EFI Fuse 21 Remove the dipstick from the oil tank Add 2 quarts 1 9 liters of the recommended oil Reinstall the dipstick 22 Start the engine and allow it to idle for 3 5 minutes Make sure the engine coolant temperature is between 145 and 160 degrees F 63 71 degrees C 23 Stop the engine 24 Remove the dipstick from the oil tank Clean the dipstick with a clean shop towel and reinsta...

Page 114: ...id overfilling If the filling and checking procedure is not completed within three min utes reinstall the dipstick Restart the engine and allow it to idle for no more than 20 seconds to circulate the oil back into the tank Continue adding and checking the oil until the level is slightly above the lower mark in the safe operating range on the dipstick Do not overfill 27 Reinstall the dipstick MODEL...

Page 115: ...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 element in paper towels or a simi lar absorbent material 5 Reinstall the dry foam element or install a new foam element NOTE Always replace a foam element that is brittle cracked...

Page 116: ...the inside of the tunnel This should take approximately two pumps Do not use more than four pumps Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as shown Front Suspension The front suspension and steering components do not require lubrica tion Fitting ...

Page 117: ...enance Table beginning on page 100 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the life of the sus pension For more information about suspension lubrication and adjust ments see your Polaris dealer M 10 136 ACE Rear Suspension IQ Comfort Rear Suspension ...

Page 118: ...numbers of Polaris products The dipstick is located on the lower front side of the gearcase Maintain the oil level in the safe operating range between the upper and lower marks on the dipstick 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 as needed Do n...

Page 119: ...oil breather ele ment See page 112 1 Position the vehicle on a level sur face 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 recommended...

Page 120: ...nd condition after the engine has been warmed up and the vehicle has been driven at higher speeds If a plug is fouled replace the plug with a new plug CAUTION Using non recommended spark plugs can result in serious engine damage A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug Always use the spar...

Page 121: ...e engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are exce...

Page 122: ...laris 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 100 Fuel Lines Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal dete rioration from weather and fuel compounds m...

Page 123: ...or more as shown tighten the belt or install a new belt Air Filter Turbo Inspect the air filter for oil and dirt accumulation at the intervals out lined in the Periodic Maintenance Table beginning on page 100 1 Open the airbox 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 Breather Filter Clean or repla...

Page 124: ...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 Carbure tor and Throttle Body Cleaner NOTE See page 151 for the part numbers of Polaris products 6 Close the hood WARNING Hot exhaust system parts can cause serious burns Allow adequate time for the exhaust...

Page 125: ...Never exceed a 60 antifreeze 40 water mixture See page 151 for the part numbers of Polaris prod ucts NOTE Never add tap water to the cooling system Minerals cause deposits 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 th...

Page 126: ...lant bottle or overflow tank Filler neck Pressure cap Connecting hoses Always maintain the coolant level at the COLD FILL mark on the cool ant tank when the engine is cold CAUTION Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recom mended COLD FILL Mark ...

Page 127: ...u must drive your snowmobile after the high temperature indicator light has illuminated drive in deep snow Drive slowly and stop frequently to allow the engine to cool down Engine performance will be reduced if you continue oper ating when the high temperature light is illuminated WARNING Steam and hot liquids will cause serious burns to your skin Never remove the pressure cap when the engine is w...

Page 128: ...ed or replaced including coolers radiator engine coolant lines and oil cooler A cooling system failure occurs resulting in coolant loss A coolant line has been disconnected for any reason A coolant leak occurs 1 Read the entire coolant bleed procedure before beginning After beginning the bleed procedure do not stop the engine until reaching step 14 2 Move the snowmobile into a well ventilated area...

Page 129: ...When the level falls add coolant A rising level is acceptable NOTE During bleeding air pockets will bubble to the surface Add coolant after these air pockets have surfaced making sure that the coolant level remains visible in the filler neck 8 With the engine idling and while making sure that the level in the filler neck remains visible observe the bleed return If the system is self bleeding prope...

Page 130: ... 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 13 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 thermostat is open and the entire cooling sys tem is bleeding If coolant is still flowing from the bleed ret...

Page 131: ... 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 3 Finger tighten the adjuster bolt 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 Adjuster Bolt Jam Nut ...

Page 132: ... is less than 1 16 1 5 mm Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops bring the snowmobile to an authorized Polaris dealer for inspection and adjustment WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that ...

Page 133: ...a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rap idly absorbs moisture from the air The moisture causes the boiling tempera ture of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury WARNING Keep the master cylinder cover free of dirt and debris The vent ...

Page 134: ...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 and release the brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles 7 After bleeding is complete refill the reservoir to the proper level See page 130...

Page 135: ...ulb 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 Reinstall the plenum co...

Page 136: ...s EFI RELAY EX SENSOR GAUGE 20A REVERSE SHIFT Exhaust sensor Gauge Reverse shift Accessory projector beam relay Diagnostic plug IGNITION 20A Ignition relay power EFI 20A Cam phase sensor ECU hold on power Reverse limit switch Forward limit switch Start relay coil Chassis relay coil Ignition relay coil Fuel pump relay coil Fan relay coil Fuel pump relay power PTO injector MAG injector Wastegate IGN...

Page 137: ...recommended center distance for your machine If adjustment is necessary see your dealer WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern see your dealer immediately Do not operate the snowmobile until repairs have been made All clutch maintenance and repairs must be performed by an authorized Polaris dealer Any unauthorized modifications ...

Page 138: ...om 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 and apply downward pressure while measuring at point A 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 2 Using a 1 8 A...

Page 139: ...e engine to come to a complete stop 3 Lock the parking brake 4 Open the hood 5 Remove the left side panel 6 Install an L wrench into the open threaded access hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves open far enough to remove the belt CAUTION Do not attempt to remove the drive belt after operating in reverse The snow mobile must be stopped after forward m...

Page 140: ...y operate in the 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 4 Reinstall the side panel 5 Close and secure the hood ...

Page 141: ...he track along the entire length of each rod Bend the track to check for break age 4 Replace the track if any rod dam age is found CAUTION Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel Always install a track having the lug size recommended for your model WARNING Broken track rods can cause a rotating track to come off the machine...

Page 142: ...the track warranty WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended periods on ice and other surfaces that have lit tle or no snow for lubrication CAUTION High speed use on hard packed surfaces is not recomm...

Page 143: ... specified distance see chart ahead of the center of the rear idler wheel NOTE Measure at the point where the weight is hanging WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine run ning TRACK TENSION DATA CHART Suspension Slack...

Page 144: ... 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 142 and adjust as necessary 11 Tighten the lock nuts 12 Tighten the idler shaf...

Page 145: ...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 2 and 3 to verify proper alignment n Rail Slide Wear For ease of inspection all...

Page 146: ...143 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners ...

Page 147: ...the skis at point X should be 1 8 to 1 4 3 6 mm greater than the measurement at point Y NOTE If the skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may also be affected WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski align ment or camber adjustment S...

Page 148: ...he snowmobile so the skis are approximately 6 15 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse the steps to install a skag WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recom...

Page 149: ...hinder vehicle per formance Follow the battery charging instructions on page 148 before installing the battery 1 Ensure that the battery is fully charged 2 Set the battery in the battery holder 3 Connect and tighten the red positive cable first 4 Connect and tighten the black negative cable last 5 Attach the hold down strap 6 Verify that cables are properly routed 7 Reinstall the left side panel W...

Page 150: ...ted dur ing 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 installa tion 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 ch...

Page 151: ...tion before and 1 2 hours after the end of charging WARNING An overheated battery may 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 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 152: ...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 148 Store the battery in a cool dry place Controls and Linkage Lubricate all bushings and cables at the intervals outlin...

Page 153: ... 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 Always tie the snowmobile to the transporting unit securely using suitable straps 3 Remove the ignition ...

Page 154: ...Chaincase Lubricant 12 oz Grease Specialized Lubricants 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 Nyogel 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 ...

Page 155: ...may be iced up or fro zen to the ground Jammed or broken chaincase sprocket or chain See your dealer Mechanical failure See your dealer Probable 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 156: ... Clogged fuel filter Replace the filter Low battery voltage Recharge the battery to 12 8 VDC Poor engine compression See your dealer Mechanical failure See your dealer Probable 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 157: ...ug Inspect clean and or replace spark plug Kinked or plugged fuel vent line Inspect and replace Clogged air filter Inspect and clean or replace Air flow through intake is too warm Turbo models Boost is limited until cooler air flows through the intake Engine management system failure See your dealer Engine overheating Stop and cool the engine See the Engine Overheating troubleshooting section on p...

Page 158: ...ator Stop and cool the engine Clean snow and debris from the radiator Probable Cause Solution Worn drive belt Replace with the recommended belt Excessive belt sheave clearance See your dealer Probable Cause Solution Incorrect belt Replace with the recommended belt Incorrect clutch alignment See your dealer Broken or loose engine mount See your dealer Probable Cause Solution Broken drive clutch com...

Page 159: ...rts from side to side Check ski alignment see page 144 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Set static sag see page 58 Check rail slide replace if worn see page 142 Install Accu Trak dual skags see your dealer Front end pushes Check for worn skags Check for binding front suspension...

Page 160: ... compression damping see your dealer Check track tension see page 140 Front end pushes Check for worn skags Check for binding suspension shafts and grease all pivot points Shorten front limiter strap Install single skags see your dealer Steering is heavy Check skags and skis for damage Check ski alignment see page 144 Make sure spindles and all steering components turn freely Verify sag dimension ...

Page 161: ... 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 perfor mance Check for fouled plugs or water ice or dirt in the gas tank or fuel line Loading machines onto trailers Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the machine com ...

Page 162: ... contained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following information 1 Serial number 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experienced 6 Length of time and conditions of operation 7 Previous correspondence Use the page pro...

Page 163: ...e owner reports theft A In addition to notifying the proper law enforcement officials the owner must call Polaris Customer Service B Owners must provide their name address telephone number and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notifyi...

Page 164: ...s 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 pur poses other than for which it was manufactured The warranty does not cover any dam ages that occur during t...

Page 165: ...st 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 Polari...

Page 166: ...overage in the event of a warranty claim This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamina...

Page 167: ...Coverage is automatic with no addi tional 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 Damage due to accident fire explosion theft or other causes beyond Polaris control Damage caused by the failure o...

Page 168: ...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 169: ...ludes 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 components exhaust gas recirculation system components and aftertreatment system components Replacing or repairing other components not covered by this warranty is the responsibility of the snowmobile owner The exclusi...

Page 170: ...ses 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 related maintenance is not performed Performance of other scheduled main tenance is strongly recommended but is not necessary to keep the emissions related warranty valid Any qualified rep...

Page 171: ...er each time your snow mobile 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 172: ...169 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 173: ...170 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 174: ... Digital Display 41 Disabled Operators 14 Drive Belt 20 135 137 Adjustment 135 Condition 135 Deflection 135 Installation 137 Removal 136 D Drive Chain Tension 128 Driver Awareness 16 Driveshaft Bearing Lubrication 113 Driving Downhill 18 Driving in Hilly Terrain 19 Driving on Slippery Surfaces 19 Driving Responsibly 22 E Electrical System 133 Emission Control Information 97 98 Emission Control Lab...

Page 175: ...oducts 151 Pre Ride Checklist 74 82 Pressure Cap Warning 24 R Rail Slide Wear 142 Rear Rear Scissor Stop 61 Rear To Front Coupling 61 Relay Label 133 Retainers Optional M 10 66 Reverse Operation 94 95 Reverse Warning 26 Rider Capacity 13 RIDER SELECT 34 36 RRSS 61 S Safety 8 23 Safety Decals 24 27 Sag M 10 63 68 Seat Latches 75 Shock Spring Preload Front 55 Shock Valving 56 Skags 73 145 Ski Alignm...

Page 176: ... 96 Track Alignment 142 Track Inspection 79 138 Track Lubrication 139 Track Replacement 138 Track Tension 140 141 Track Warm Up 90 91 Track Warning 25 T Traction Products 72 73 Transporting the Snowmobile 150 Troubleshooting Drive Belt Wear Burn 158 Engine and Drive Train 152 155 IQ Suspension 156 M 10 Suspension 157 Trunk Cruiser 32 Turbo Noise FST 93 V Vehicle Identification Numbers 7 W Warning ...

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