Polaris FST IQ Touring Page 124 Owner'S Manual Download

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121

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause spongy brake lever action.

Bleed the system before operating the snowmobile.

WARNING!

Operating the vehicle with a spongy brake lever can result in loss of

brakes, which could cause an accident and lead to serious injury or death.

Never operate the vehicle with a spongy-feeling brake lever.

During the bleeding procedure, keep the brake handle as level as possi-

ble. The reservoir must be in this position to minimize the possibility of

air entering the system through the reservoir vent.
1. Remove brake master cylinder reservoir cover and gasket.
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 open-

ing. 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 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.

WARNING!

Overfilling the master cylinder leaves no room for fluid expansion

and may cause the brakes to lock, resulting in serious injury or death. Always

add brake fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level.

See page 120.

8. Reinstall the gasket and cover.

Summary of Contents for FST IQ Touring

Page 1: ......

Page 2: ...antone 425C For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922571 Rev 01 Printed in USA ...

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: ...improvements 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 ...

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 66 This section explains procedures that must be performed before riding Operation 75 This section explains proper engine break in operation of features and general operating procedures Maintenance 89 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: ...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: ...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: ...heir meanings before reading the manual The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage...

Page 12: ...e 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 opera tion with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become ...

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 igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its o...

Page 14: ...s 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 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...

Page 15: ...r 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 pre...

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: ...sical 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 Cargo Overload Too much weight on the rear of the snowmobile 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 ...

Page 18: ...the trail ahead If your speed is 40 MPH 64 km h your snowmobile is traveling about 60 feet 18 m per second If you look back for only two seconds your snowmobile 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 ove...

Page 19: ...view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness Always check with local residents or authorities for general information on conditions when traveling on lakes and streams that are strange to you Before riding your snowmobile on a frozen body of water be sure the ice is thick enough to support the snowmobile and its operator as w...

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: ...m 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 the...

Page 22: ... 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 continue...

Page 23: ... at high speeds 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...

Page 24: ... 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 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...

Page 25: ...well 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 sn...

Page 26: ... 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 4 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: ...ragging the snowmobile 4 Hood 5 Headlight 6 Windshield 7 Operator Seat 8 Passenger Seat 9 Backrest 10 Passenger Grab Handle 11 Cargo Bag 12 Grab Handle Heater Switch 13 Taillights 14 Rear Bumper 15 Snow Flap 16 Track 17 Suspension 3 4 5 6 2 1 7 8 9 12 13 14 15 16 17 10 11 ...

Page 32: ... 6 Hood Hold Down Straps 7 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 Ignition Switch 16 1 13 14 15 12 7 8 9 10 11 3 1 6 4 5 ...

Page 33: ...ve the backrest for ward for operator use or rear ward for passenger use 3 Always tighten the knobs securely after adjusting Adjustable Headlights Move the adjuster to the left to lower the headlight beam Move the adjuster to the right to raise the headlight beam Radiator Compartment Access Panel The access panel is provided for cleaning debris from the radiator Operator Passenger Raise Lower ...

Page 34: ...ure 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 Reverse the procedure to reinstall the seat Press down firmly on both sides of the seat to engage the latch Verify that the latch ...

Page 35: ...ted for rider preference 1 Unscrew and remove the knob assemblies that secure the grab handles 2 Reposition the grab handles to one of the three available posi tions on the grab handle tube between the operator seat and the passenger seat 3 Reinstall the knob assemblies and tighten securely Knob Assembly ...

Page 36: ...cket 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 upper console WARNING Serious injury could occur if sparks ignite a fuel supply Do not install an accessory 12 volt DC outlet on the upper console Install the outlet in the recoil pocket ...

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

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 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 This could...

Page 40: ... cause of a flashing MIL or high temperature indicator serious engine damage may occur with continued operation See your Polaris dealer 1 Verify that all electrical connections are secure 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 flas...

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: ...r stutter 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 wi...

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: ...or 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 Turbo mode...

Page 45: ...ng or with the engine off If the engine is off make sure the stop switch is pressed down and turn the ignition key to the START position briefly to activate the gauge The gauge will illuminate for about 90 seconds Standard vs Metric The MFD will 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 ...

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: ...d 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 Settings Trip 1 and Trip 2 ...

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: ...e seconds 4 When the hour starts flashing press the SET switch once to advance one hour 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 If the MODE button is not pressed within ten seconds the ...

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: ... quickly by 100 foot 30 m incre ments 5 Adjust the altitude display to within 50 ft 15 m of current altitude Tip 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...

Page 52: ...d 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 Tip The MPH and RPM values are both reset at the same time Reset the values 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 Tip 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 o...

Page 55: ...ry 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 wires to separate the heat sealed seams Squeeze the corners of the compart ment inward so the batte...

Page 56: ...Make 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 clo...

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: ...e 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 spring rates can be adjusted by changing the nitrogen pressure The upper chamber adjusts the main spring rate The ...

Page 60: ...ee 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 ...

Page 61: ...r seated 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 measurement Y from X sag X Y If the measured sag is incorrect adjust the FRA position and or rear torsion spring preload Tip This is only an initial setup and final spring preload may vary based on rider p...

Page 62: ...tly more effort Different rate torsion springs are available if a firmer ride is desired See your dealer for more information Suspension Coupling On all Polaris snowmobile rear suspensions there are two torque arms that control the movement of the rail beam Prior to the advent of sus pension coupling these torque arms could move independently of each other Rear suspension coupling links the moveme...

Page 63: ...ate for all riders and conditions Rear To Front Coupling and the Rear Rear Scissor Stop RRSS The rear rear scissor stop RRSS couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen dent movement between the rear torque and the front torque arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight ...

Page 64: ...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 Tip Your dealer can help you with initial setup and additional setup instruc tions to help you achieve your opti mum ride A scissor stop tool is also available...

Page 65: ...the adjuster block turn han dlebar to left or right for access to back nuts Tip 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 snowmobile when turned fully to the left or right 4 Torque the front bolts first then torq...

Page 66: ...snowmobile 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 Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service ...

Page 67: ...ck of clearance between upper carrier wheels and track Use of studs longer than the recommended length on snowmobiles 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 abil ity may be reduced on hard packed snow or ice When st...

Page 68: ...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 69: ...k Brake Lever Brake System 69 70 119 Throttle Lever 67 Throttle Safety Switch 67 Auxiliary Shut Off Switch Engine Stop Switch 73 87 Ignition Switch 73 87 Taillight Brakelight Headlight 73 Coolant Level 113 Gearcase Oil Level 105 Engine Oil Level 94 Engine Oil Level check before operating if vehicle was tipped over 74 Foam Oil Breather Element 102 Suspension Mounting Bolts 72 Skags Wear Bars 65 135...

Page 70: ...The manual is your guide to safe and enjoyable snowmobiling experience n Throttle Lever The throttle and brake are the 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 no...

Page 71: ...place before operating the snowmo bile 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 72: ...ulic system Refer to the brake bleeding infor mation on page 121 Brake Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 120 Check for the presence of air in the fluid system See page 121 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 73: ... 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 74: ...hicle WARNING 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 Track damag...

Page 75: ...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 131 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 132 Track Tension 130 All rear suspension components Lubrication 104 Ski r...

Page 76: ...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 77: ... its left side Clean the element if oil is present See page 102 NOTICE Operating the snowmobile with a clogged foam oil breather element can result in severe engine damage Always clean or replace the element as recommended 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 dama...

Page 78: ...rks in or near the area where refu eling 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 The engine exhaust from this product contains chemicals k...

Page 79: ...mage close fitting engine parts Do not operate at full throttle or high speeds for extended periods during the break in period NOTICE 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 81 2 Check the oil level in the oil tank See page 94 Add oil if necessary to maintain at the...

Page 80: ...s attempt to start the engine without using the throt tle If two to three attempts are unsuccessful apply 1 8 to 1 4 throttle while cranking the engine Ease off the throttle immediately when 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...

Page 81: ...ect the negative usually black cable last When removing jumper cables always disconnect the negative usually black cable first WARNING Loose fitting clothing can get caught in the engine when the vehicle is running with the hood open This can cause serious injury or death Remove or control all items that could catch in the engine including scarves gloves jackets and clothing straps and hooks NOTIC...

Page 82: ...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 NOTICE Make sure that the end of the negative cable by the weak battery is not contact...

Page 83: ...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 84: ...age paint Always protect painted surfaces 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 snowmo bile to run out of fuel Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of is...

Page 85: ...hile warming up the track Do not use excessive throttle dur ing warm up or when the track is free hanging Be sure the rear support is sta ble Use of traction products such as studs ice growsers etc will increase the possi bility 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 snowmobile WARNIN...

Page 86: ...ff 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 Tip It will take longer to warm up the track sufficiently during colder outdoor 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 87: ...ause vehi cle speed and engine speed to be limited WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not limit engine speed to 2400 RPM when all pressure is removed from the throttle lever during a throttle malfunction immediately push down the engine stop switch Do not start th...

Page 88: ... several times The lever and cable must return to the idle position quickly and completely 4 If the throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 If the engine doesn t start take the snowmobile to an authorized Polaris dealer for service Tip Excessive freeplay in the throttle cable may cause the safety switch to acti vate preventing the en...

Page 89: ...Look behind the snowmobile before and while backing Avoid sharp turns Apply throttle slowly NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your snowmobile is clear...

Page 90: ... 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 84 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 91: ...e of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used If passengers are to be 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...

Page 92: ... 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 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups ar...

Page 93: ...r 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 procedures and the use of tools or if you don t feel ...

Page 94: ...aler for service O Brake Lever 69 Check lever travel and lever feel O Coolant 113 Inspect level add as needed O Brake fluid 120 O CHANGE EVERY 2 YEARS Hood Latches 68 Secure properly replace if damaged O Seat Latches 67 O Rail Slide 132 Inspect for wear or damage replace when worn O Foam Oil Breather Element 102 Check pre ride clean or replace with each oil change Check clean after tipping onto le...

Page 95: ... O O O Handlebars Verify alignment adjust as needed O O O Drive Chain 118 Verify tension adjust as needed EVERY Gearcase Oil 105 Check at 500 mi 800 km change every 1000 mi 1600 km O EVERY 1000 1600 Rear Suspension 104 Lubricate pivot shafts more often in wet snow condi tions O O Bearings 103 139 Lubricate drive shaft and jackshaft bearings O O Throttle Cable 103 Lubricate O O Clutches 124 Verify ...

Page 96: ...proper routing replace as needed O O Brake Pads Disc 119 Inspect replace if worn or damaged O O Fuel Vent Lines 109 Inspect replace if worn or damaged O O Ski Toe 134 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 Specifications Intake 0 08 0 15 mm Exhaust 0 18 ...

Page 97: ...ndations for ambient tempera ture operation NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands n Oil Level Check Read the entire oil check procedure before checking the oil level The oil level will rise as engine temperature increases The oil level will be lower when the engine is cold To obtain a pr...

Page 98: ...perature 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 Tip Check the oil level within three minutes before the coolant tem perature and oil level begin to drop 5 Remove the...

Page 99: ...e bottom of the safe operating range on the dipstick 9 If the level is high remove 2 ounces 60 ml and recheck the level NOTICE Do not overfill the oil tank Engine damage may occur Always add oil in small increments and recheck the level to avoid overfilling 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 ...

Page 100: ...level check procedure begin ning on page 94 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 94 6 If oil is not present add another 1 2 quart 47 l of oil Reinstall the dipstick star...

Page 101: ... turn over the engine without starting 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 CAUTION Hot oil and a hot exhaus...

Page 102: ...rom the fuse block 11 Reinstall the right 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 103: ... 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 104: ...d overfilling If the filling and checking procedure is not completed within three minutes rein stall 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 check ing the oil until the level is slightly above the lower mark in the safe operat ing range on the dipstick Do not overfill 27 Reinstall the dipstick MODE...

Page 105: ...lement as recommended The foam oil breather element is located inside the airbox 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 Tip If soap and water are not readily avail able remove as much liquid as possible by pressing the foam element in paper towels or ...

Page 106: ...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 107: ... Periodic Maintenance Table beginning on page 91 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 IQ Comfort Rear Suspension ...

Page 108: ...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 109: ...l breather element See page 102 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 Tip 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 oil...

Page 110: ...than intended for that plug Always use the spark plugs recommended for your snowmobile Use recommended spark plugs with the proper gap Refer to your Owner s Manual Supplement for the specific spark plug to be used in your snowmobile Use only resistor type spark plugs Torque spark plugs to 18 20 ft lbs 24 27 Nm Check the spark plug firing end condition after the engine has been warmed up and the ve...

Page 111: ...e engine and the service Tip The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjust ments 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 112: ...olaris 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 91 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 113: ...he 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 91 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 replace the breather element at ...

Page 114: ...er 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 Carbure tor and Throttle Body Cleaner See page ...

Page 115: ...ater Never exceed a 60 antifreeze 40 water mixture See page 141 for the part numbers of Polaris prod ucts Tip 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 fo...

Page 116: ...oir bottle Filler neck Pressure cap Coolant overflow tank Connecting hoses Always maintain the coolant level at the COLD FILL mark on the cool ant overflow tank when the engine is cold NOTICE Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recommended COLD FILL Mark ...

Page 117: ... your skin Never remove the pressure cap when the engine is warm or hot or if any part of the cooling system is warm or hot NOTICE Operating the snowmobile when the high temperature indicator light is illuminated can result in serious engine damage Always stop the snowmobile and cool the engine when the high temperature indicator light illuminates Drive in adequate snow to prevent overheating If y...

Page 118: ... service Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main tenance Table beginning on page 91 In addition bleed the cooling sys tem any time one or more of the following conditions exist A component of the cooling system has been serviced or replaced including coolers radiator engine coolant lines and oil cooler A cooling system failure occurs resu...

Page 119: ...the filler neck until the coolant level reaches the top of the rear cool ing loop return line on the inside of the filler neck The opaque coolant reservoir bottle should be full but may have a small air bubble in the top CAUTION Never start the engine when the pressure cap is removed 6 Reinstall the pressure cap Start the engine and allow it to idle 7 With the engine idling observe the coolant lev...

Page 120: ...e cap and add coolant through the filler neck until the reservoir bottle is full Reinstall the pressure cap and start the engine 12 Repeat steps 10 11 until the the coolant level in the bottle no longer falls at an engine temperature of 185 F 85 C or greater 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 indi...

Page 121: ... 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 122: ...re 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 Brake Disc Bleed Screw Brake Line Brake Caliper Brake Pad Material Replace when thickness is less than 1 16 1 5 mm Excessive Lever Travel Hydraulic b...

Page 123: ...low for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function NOTICE 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 tem perature brake fluid See page 141 for the part numbers of Polaris products The brake fluid ...

Page 124: ... 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 open ing 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 a...

Page 125: ...lb 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 cov...

Page 126: ...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 127: ...ust be performed by an authorized Polaris dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty NOTICE The bushings in 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 Offset Clutch alignment offset is important for maintaining optimum perfor m...

Page 128: ...oom 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 ...

Page 129: ...s 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 Rotate the driven clutch counterclockwise 1 4 turn by hand to ensure forward engagement before attempt ing to remove the belt 7 Install an L wrench into the open threaded access...

Page 130: ...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 131: ...commended for your model Track Inspection WARNING Broken track rods can cause a rotating track to come off the snowmobile 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 sup port the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track ...

Page 132: ...ide 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 Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty NOTICE High speed use on hard packed surfaces is not recommende...

Page 133: ...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 snowmo bile and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel Tip Measure at the point where the weight is hanging TRACK TENSION DATA CHART Sus...

Page 134: ... to provide equal adjustment on both sides of the track 8 Repeat the measurement on the other side of the track Tip 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 132 and adjust as necessary 11 Tighten the lock nuts 12 Tighten the idler shaft...

Page 135: ...aced 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 Polaris rail...

Page 136: ...133 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners ...

Page 137: ...ith 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 3 6 mm greater than the measurement at point Y Tip If the skis are misaligned we recommend that your dealer correct the align ment since camber adjustment...

Page 138: ...ed snow or ice Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter Tip Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement Some models are equipped with single skags Some models are equipped with dual skags 1 Raise and support the front of the snowmobile so...

Page 139: ...ry 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 dam age the battery and result in a shorter life It can also hinder vehicle per formance Follow the battery charging instructions on page 138 before installing the battery 1 Ensure that t...

Page 140: ...ted 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 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 cha...

Page 141: ... 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 Tip Always verify battery condition before and 1 2 hours after the end of charg ing 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 142: ... 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 138 Store the battery in a cool dry place Controls and Linkage Lubricate all bushings and cables at the intervals outli...

Page 143: ...cured 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 Alwa...

Page 144: ...le Engine Oil gal 2874443 VES II Synthetic 2 Cycle Engine Oil 2 5 gal Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic 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...

Page 145: ...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 146: ... 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 147: ...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 148: ...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 149: ...arts from side to side Check ski alignment see page 134 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 132 Install Accu Trak dual skags see your dealer Front end pushes Check for worn skags Check for binding front suspensio...

Page 150: ...arm the engine at least five minutes Take the drive belt off the snowmobile in extremely cold weather and warm it up Break snowmobile 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 snowmo biles onto trailers Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the snow...

Page 151: ... 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 152: ...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 153: ...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 154: ...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 155: ...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 156: ...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 157: ...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 158: ...components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the followin...

Page 159: ...due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for perform...

Page 160: ...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 161: ...158 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 162: ...159 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 163: ...tem Bleeding 115 117 Cooling System Flushing 115 D DC Outlet 12 Volt 33 Digital Display 41 Disabled Operators 14 Drive Belt 20 Drive Belt Adjustment 125 Drive Belt Condition 125 Drive Belt Deflection 125 Drive Belt Installation 127 Drive Belt Removal 126 Drive Chain Tension 118 Driver Awareness 16 Driveshaft Bearing Lubrication 103 Driving Downhill 18 Driving on Slippery Surfaces 19 Driving on Slo...

Page 164: ...D Components 41 MFD Digital Display Programs 44 51 MFD Settings 42 43 N Noise 6 O Oil Engine 94 101 Gearcase 105 106 Oil Breather Element 102 Oil Breather Filter 110 Oil Change 98 101 Oil in System Check 97 Oil Level Check 94 96 Operating in Deep Snow 21 Operation Warning 27 P Parking Brake Lever Lock 70 Passenger Warning 25 Polaris Products 141 Pre Ride Checklist 66 74 Pressure Cap Warning 24 R R...

Page 165: ...rmance Tips 57 Suspension Front 54 Switch Stop 84 Switch Throttle Safety 84 T Throttle Cable Lubrication 103 Throttle Lever 67 85 Throttle Safety Switch 67 84 Tip Over Inspections 74 Torsion Spring Preload IQ 59 Towing 88 Track Alignment 132 Track Inspection 71 128 Track Lubrication 129 Track Replacement 128 Track Tension 130 131 Track Warm Up 82 83 Track Warning 25 Traction Products 64 65 Transpo...

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Polaris FST IQ Touring, Owner'S Manual

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