Polaris Touring 2004 Owner'S Manual Download Page 130

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128

TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause

Solution

Noise in drive
system

Broken drive clutch

components

SEE YOUR DEALER.

Bearing failure/

chaincase, jackshaft,

or front drive shaft

SEE YOUR DEALER.

Drive belt surface flat

spots

Inspect and replace if necessary.

Drive chain loose or

worn, sprocket teeth

broken

Inspect and adjust or replace.

Poor low RPM

Worn drive belt

Inspect and replace if necessary.

performance

Excessive belt/sheave

clearance

SEE YOUR DEALER.

Loose torque stop

Inspect and adjust.

Sticky clutch

SEE YOUR DEALER.

Engine doesn’t
start (electric
start models)

Wire connections

SEE YOUR DEALER.

Engine doesn’t
turn

Seized engine

SEE YOUR DEALER. Seizure is a result

of poor lubrication, inadequate fuel supply,

broken parts, or improper cooling.

Hydrostatic lock

Fuel may have entered crankcase while ve-

hicle was standing or being transported.

SEE YOUR DEALER to correct cause.

Drain plug(s) are located on lower crank-

case for emergency draining.

Summary of Contents for Touring 2004

Page 1: ...2004 Touring WideTrak Snowmobiles 2004 Touring WideTrak Snowmobiles Owner s Manual for Vehicle Maintenance and Safety Owner s Manual for Vehicle Maintenance and Safety...

Page 2: ...haust from this product contains chemicals known to cause cancer birth defects or other reproductive harm PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust which contain chemicals k...

Page 3: ...A Polaris owner s Web site designed just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it ou...

Page 4: ...uction components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for ref...

Page 5: ...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 abou...

Page 6: ...Perfect Fit 30 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 51 This section explains procedures that must be performed b...

Page 7: ...ur model may differ n Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage...

Page 8: ...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...

Page 9: ...numbers are essential to its recovery and identification Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys...

Page 10: ...n your vehicle or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert cauti...

Page 11: ...We strongly recommend that the operator check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failur...

Page 12: ...engine running Turn off the ignition raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation Never hold the snowmobile up or sta...

Page 13: ...propriate to the conditions you may encounter Such equipment may include but is not limited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire a...

Page 14: ...rider active vehicle requires good judgement and physical skills Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or dea...

Page 15: ...n the distance illuminated by the headlight Rider Capacities Driving 1 Up Some Polaris snowmobiles are designed for a single rider only A decal on the console of these models indicates single rider op...

Page 16: ...ur 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 con...

Page 17: ...now or ice may lead to loss of vehicle control and result in serious injury or death Slow down to maintain control under these conditions It s dangerous to drive on ice or other slippery surfaces If i...

Page 18: ...er side of the hill If you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling bac...

Page 19: ...remote don t defeat the purpose of the guard by removing it It s provided for your safety Drive Belt Do not operate the engine with the drive belt removed Any servicing that requires operation without...

Page 20: ...track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the machine into motion but always operate within safety limits and on 2 Up machines wi...

Page 21: ...track and or engine If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the throttle is opened the snowmobile will b...

Page 22: ...if they ve taken a snow mobile safety course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safe ty course Everyone can benefit from the cour...

Page 23: ...26 10 6 21 37 53 69 85 100 116 132 148 Wind Speeds Great er Than 40 MPH Have Little Added Little Danger For Properly Clothed Person Increasing Danger Great Danger Have Little Added Effect Clothed Per...

Page 24: ...The part number is printed on the decal Clutch Cover Warning This warning decal is found under the hood on the clutch cover Do not operate engine with hood open Do not attempt adjustment with engine r...

Page 25: ...ies the maximum recommended weight capacity for the carrier Never exceed the maximum recommended weight capacity for your machine Passenger Warning Polaris touring models and the WideTrak are designed...

Page 26: ...24 SAFETY Safety Decals and Locations Standard Reverse Warning The Polaris WideTrak snowmobile is equipped with standard reverse The reverse warning decal is located above the instrument housing...

Page 27: ...25 SAFETY Safety Decals and Locations Electronic Reverse Warning Polaris snowmobiles equipped with electronic reverse will have the electronic reverse warning decal WARNING AVERTISSEMENT...

Page 28: ...6 SAFETY Safety Decals and Locations Operation Warning Operation warning decals are present on the console of all Polaris snowmobiles in both French and English Touring Models WideTrak WARNING WARNING...

Page 29: ...27 SAFETY Safety Decals and Locations Operation Warning Touring Models WideTrak AVERTISSEMENT AVERTISSEMENT...

Page 30: ...1 Fuel Filler Cap 2 Ignition Switch 3 Accessory Plug 4 Brake Lever 5 Electronic Fuel Gauge 6 Speedometer 7 Tachometer 8 Electric Shock Control Gauge 9 Engine Stop Switch 10 Throttle Control 11 Hood H...

Page 31: ...Seat 6 Backrest 7 Storage Compartment 8 Taillights 9 Rear Bumper 10 Snow Flap 11 Passenger Hand Hold 12 Track 13 Suspension 14 Trailing Arm 15 Nosepan 16 Front Bumper 17 Skis 18 Passenger Hand Hold St...

Page 32: ...r each adjustment until the best ride is achieved Independent Front Suspension IFS The IFS is made up of the skis 1 front shocks and springs 2 and the components that connect these parts to both the s...

Page 33: ...ide the machine The bumper will move up on the rod in relation to the amount of travel that was used during the ride If the travel is full the bumper will be seated at the top of the rod Shock Absorbe...

Page 34: ...used to achieve the desired ride The shocks have a wide range of adjustment capability By turning the screw clockwise the compression of the shock increases stiffening the ride When adjusting these s...

Page 35: ...d Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension Never exceed one inch of preload beyond the factory settings and ensu...

Page 36: ...if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness See your Polaris dealer for more information Changing shock valving on RydeFX and RydeFX SOL...

Page 37: ...e For further assistance see your dealer Suspension Performance Tips S Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding style W...

Page 38: ...d measure the distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y...

Page 39: ...riding style A Low tension B Medium tension C High tension Indy Select Rear Shock The Indy Select rear shock allows for adjustments to the compression valving Locate the adjustment screw A near the ba...

Page 40: ...sion coupling links the movement of the front and rear torque arms to each other There are two types of rear suspension coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS The front r...

Page 41: ...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 to transfer to the rear resulting in improved cornering pe...

Page 42: ...to a higher position with the scissor stop tool 1 located in your tool kit To increase weight transfer or ski lift during acceleration move the RRSS to the rearward hole on high position The RRSS may...

Page 43: ...the cam up B Front Track Spring and Preload Front track spring and preload can also be adjusted Turn the screw C clockwise to tighten compression stiffen Turn the spring D clockwise to tighten preload...

Page 44: ...he rail beam 3 Using a 9 16 wrench loosen the jam nuts B on the preload bolts 4 Adjust the preload bolts C to the desired RCA position 5 Tighten the jam nuts B NOTE Make sure the preload bolt con tact...

Page 45: ...e current ACE position 2 If the soft or firm switch is pressed more than one time in succession it will adjust as many increments as the switch is pressed The electronics will do the math for the user...

Page 46: ...move one position can take up to 12 seconds depending on the rear shock loads Due to alternator limitations the ACE module will operate only at engine speeds above 3500 RPM Similar to the RCA on the s...

Page 47: ...the ground and the same spot on the running board The difference between the two readings should be approximately 1 1 2 3 8 cm If the difference is greater than 1 1 2 the rear spring should be adjuste...

Page 48: ...the adjuster block turn handlebar to left or right for access to back nuts NOTE It may be necessary to pry the adjuster blocks apart with a screw driver 3 Adjust the handlebar to the desired height Be...

Page 49: ...l models Order PN 2870668 Use only Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in S Non compliance with government industry requirements...

Page 50: ...the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain The addition of carbide skags is recommended with studded tracks to help maintain proper vehicle steering and...

Page 51: ...2 86 cm from the outside edge of the track CAUTION If traction products are added to the track wear strips must be installed in the tunnel to avoid excessive wear Never add shims to the wear strip Tra...

Page 52: ...lled Refer to your Owner s Manual Supplement to determine if your model has wear strips Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction ac...

Page 53: ...s evenly and smoothly The lever should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly DO NOT start the engine Have the throttle servic...

Page 54: ...the brake lever Proper operation depends on an adequate supply of air and moisture free hydraulic brake fluid in the system If the brake lever feels spongy when squeezed check the level and condition...

Page 55: ...eze the brake handle and push forward on the brake lever lock Hold the lock forward and release the brake handle If the brake handle is squeezed tightly enough the lock will move freely into place Do...

Page 56: ...track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure caused...

Page 57: ...brake light for normal operation n Mirror Adjustment If equipped adjust your mirrors so they can be used to their full advantage n Check Surroundings to Verify Clear Operating Area Make sure you have...

Page 58: ...nd track resulting in premature wear and failure Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating on ice...

Page 59: ...ave the machine in this position for more than five minutes Engine RPM must be at idle before shifting the transmission Starting a Warm Engine 1 Turn the key to ON 2 Pull the kill switch shut off swit...

Page 60: ...three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle openings and ma...

Page 61: ...highest performance products available for your snowmobile s engine Refer to the table below to determine the recommended oils for use in your Polaris snowmobile Never mix brands of oil Serious chemic...

Page 62: ...hem from side to side This will loosen frozen snow from the ski bottoms allowing the machine to move forward more easily 6 The engine drive system and track are now properly warmed up and the machine...

Page 63: ...the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed...

Page 64: ...r higher turn the key switch to ON PREM When the engine is started a yellow Premium Fuel light illuminates on the instrument panel When the key is in this position the fuel must be a minimum of 91 oct...

Page 65: ...s per gallon 8 16 milliliters per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol See page 126 for...

Page 66: ...are compatible with each other Always maintain the oil level above the tank s low level line especially when the machine is operated in mountainous terrain Maintaining the proper oil level will preve...

Page 67: ...s on most Polaris models are calibrated for an altitude of 0 2000 ft 0 600 meters and ambient temperatures between 10 to 10 F 23 to 12 C All carburetors must be re calibrated if operated outside this...

Page 68: ...on shown in the illustration B Apply a slight amount of throttle A properly functioning switch must shut down the engine The throttle safety switch is designed to stop the engine whenever all pressure...

Page 69: ...n the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the machine to an authorized Polaris dealer for service If an emergency exists an...

Page 70: ...ngine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Throttle Safety Switch Interrupts ignition circuit All Tether Switch Option Interrupts ignition circuit All Excessive or...

Page 71: ...utch guard 2 Push on the inner sheave of the clutch and rotate clockwise slightly to relieve belt tension 3 Starting at one of the tower struts wind the strap counterclockwise around the clutch as sho...

Page 72: ...dicated by the shift lever Apply the throttle slowly until you re sure which gear is engaged Sometimes the drive belt will drag in the drive clutch causing slight tension in the transmission and makin...

Page 73: ...Model 5000 Trail Touring Sport Touring 5500 Indy 340 Touring 6000 All other Touring models Misfire Mode Fan Cooled Models Air flow on fan cooled models is limited during reverse operation due to reve...

Page 74: ...fore towing and have a rider on the towed snowmobile to operate the brake and steering when necessary Objects towed with a rope have no braking power and can easily collide with the rear of the snowmo...

Page 75: ...ontinue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the register...

Page 76: ...lever operation Daily 51 66 Check operation of headlights taillight brakelight Daily 55 Check park brake function Daily 53 Secure hood Daily 54 Check track alignment X 112 Steering arm and tie rod en...

Page 77: ...vot X X X 78 Flush Chaincase X X 83 Grease driveshaft bearing always perform before storage X X 80 Check and drain water trap X X 88 Grease rear suspension pivot shafts X X 79 Grease jackshaft bearing...

Page 78: ...ile 240 km Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 500 Mile 800 km Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Tec...

Page 79: ...Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Type of Service Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technici...

Page 80: ...nd right spindles Raise the front end of the ma chine to permit better grease entry into the spindle area S Lubricate both of the front ski pivots at the fittings as shown S Grease the jackshaft and d...

Page 81: ...rage each year Lack of lubrication will adversely affect your ride and the life of the suspension For detailed information about suspension lubrication and adjustments see your Polaris dealer NOTE The...

Page 82: ...ring seal may take only two pumps Push the clutch back onto the shaft and replace the clutch retaining bolt Torque to 18 ft lbs 24 4 Nm Driveshaft Bearing Greasing Inject grease into the fitting on th...

Page 83: ...f turn the handlebars to the left and lubricate liberally as shown Choke and Cable Lubricate the choke slide 2 and cables lightly with oil or grease Before turning the engine off operate the choke int...

Page 84: ...d be between the safe marks on the dipstick A See your Polaris dealer for the recommended oil for your machine Do not overfill NOTE Clean the magnetic plug B every 500 miles 800 km and whenev er check...

Page 85: ...level surface The oil level should be between the safe marks on the dipstick A Add Polaris chaincase oil PN 2871280 through the dipstick opening Do not overfill See page 126 for the part numbers of Po...

Page 86: ...ailure Refer to your Owner s Manual Supplement for the specific spark plug to be used in your machine A new engine can cause temporary spark plug fouling due to the preservative added during the assem...

Page 87: ...at range for the 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 carburetion adjustments 2 Wet...

Page 88: ...odically to remove any accumulation of snow NOTE These illustrations are general representations Your model may differ 1 Intake Foam Filter 2 Air Intake Box Operating the snowmobile with the intake fi...

Page 89: ...nance follow the oil recommendation chart on page 59 The use of other lubricants may cause improper function of the valve mech anism and increase the frequency of required cleaning due to excessive bu...

Page 90: ...ff 2 Position a container or shop towels to catch the contaminated gasoline 3 Slide the clamp 1 away from the drain plug 2 and remove the drain plug from the sediment tube 4 Wipe residue from the plug...

Page 91: ...We strongly recommend the use of only Polaris replacement parts Edge models use an oil filter that s built into the oil sending unit located in the bottom of the oil tank After changing the oil filter...

Page 92: ...re synchronized or balanced is important Properly adjusted carburetors can greatly improve engine performance fuel economy engine life and reliability If you notice any of the following conditions the...

Page 93: ...Check for weak or missing retaining springs or damper support grommets Engine Cooling Liquid Cooled Models The cooling system on liquid cooled models consists of the following major components S Coola...

Page 94: ...models If the engine coolant reaches a certain temperature the switch completes a circuit that turns the light on If you must drive your machine after the high temperature indicator light has come on...

Page 95: ...y System WideTrak If the coolant level becomes low in the coolant bottle bleed the system of any trapped air Visually inspect the coolant filter A and replace it if it s dirty 1 Fill the coolant bottl...

Page 96: ...t bottle to the maximum mark 5 Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air 6 Stop the engine and check the coolant bot...

Page 97: ...to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut A 3 Finger tighten the adjuster bolt B until it can no longer be ad...

Page 98: ...e replaced when the brake pad material becomes thinner than the backing plate approximately 1 16 A kit is available for replacing brake pads See your dealer A Brake failure during operation can result...

Page 99: ...g Plate 5 Brake Pad Material Replace when thickness is less than 1 16 Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops as described on page 96 t...

Page 100: ...uid to bring the level up to the top of the fluid level mark on the inside of the reservoir After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle...

Page 101: ...der 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 rele...

Page 102: ...block To inspect firmly depress the brake lever and measure the distance between the lever and the brake block This distance should be no more than 3 4 1 9 cm If brake lever reserve exceeds this amoun...

Page 103: ...he center of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be a...

Page 104: ...y metal base and carefully separate bulb from harness Installing the Bulb 1 Hold bulb by metal base and install into wire harness 2 Insert bulb into housing 3 Carefully flip spring back into housing p...

Page 105: ...ght Replacement 1 Remove the rear storage cover A if equipped 2 Depending on your model remove the screws B securing either the taillight housing C or the lens cover D 3 Remove and replace the bulb E...

Page 106: ...only O E M belts be used Other belts may match the dimensions but can drastically change the shift pattern resulting in poor performance See your dealer for service and adjustments NOTE A worn belt w...

Page 107: ...Drive Belt Removal 1 Be sure the key switch is off and the engine has come to a complete stop Apply the brake or lock the parking brake if equipped 2 Open the hood remove the clutch guard retaining p...

Page 108: ...in the belt removal procedures 2 Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves 3 Hold the belt down between the sheaves and roll t...

Page 109: ...cam counterclockwise to reduce the distance between the sheaves Do not rotate past the 1 position 3 Torque the bolts to 4 6 ft lbs 5 4 8 Nm TEAM Clutch 1 Loosen the 7 16 jam nut on the belt width adj...

Page 110: ...t installed it s especially important to maintain track tension as specified on page 111 Allow the engine to reach idle speed before attempting to shift into or out of reverse 2 1 Improper track tensi...

Page 111: ...Tubular Socket 4 Tubular Socket Handle 5 Wrench 6 Flat Screwdriver 7 Shielded Screwdriver only models with Indy Select or AFX shocks 8 Box End Wrench Always keep the tool kit with the snowmobile If n...

Page 112: ...ice tune up with your Polaris dealer His experienced and trained service technician will keep your machine in peak operating condition Maintenance Items The tools and maintenance items mentioned in th...

Page 113: ...the plastic Hi fax C If the track needs adjustment 5 Loosen rear idler shaft bolts D and locknuts A 6 Tighten or loosen the track adjusting screws B as necessary to provide equal adjustment on both si...

Page 114: ...to the track and slide rail 1 Safely support the rear of the machine with the track off the ground 2 Start the engine and apply a small amount of throttle until the track turns slowly at least five co...

Page 115: ...sive wear NOTE If excessive Hi fax wear occurs due to poor snow conditions additional wheel kits are available See your dealer for more information NOTE Track damage or failure caused by operation on...

Page 116: ...easurement between the skis at point X should be 1 8 to 1 4 greater than the measurement at point Y NOTE If the skis are misaligned we recommend that your dealer correct the alignment since camber adj...

Page 117: ...115 MAINTENANCE Steering System Edge IFS WideTrak X Y 10 10 10 10 X Y...

Page 118: ...Inspection and Adjustment Each week or before a long ride check fasteners and tighten if necessary Specific fasteners that should be checked are marked with a in the following illustrations All Steer...

Page 119: ...ng hardware and pry the skag downward 3 Remove the forward portion of the skag Reverse this procedure for new skag installation Worn skis and or skags will adversely affect handling Loss of vehicle co...

Page 120: ...rail A Replace Hi fax when a thickness of 7 16 is reached 3 8 on WideTrak models See your dealer for Hi fax replacement If excessive Hi fax wear occurs due to poor snow conditions additional wheel ki...

Page 121: ...er skag condition Extended Storage Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components Cleanin...

Page 122: ...he engine must be fogged with fogging oil Follow the engine fogging instructions provided on the can See page 126 Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank See...

Page 123: ...BDC the lowest position in the cylinder On twin cylinder models the opposite piston will be up 5 Pour approximately two ounces of Polaris injector oil into the spark plug hole 6 Wait one to two minut...

Page 124: ...on Transporting the Snowmobile Whenever the snowmobile is transported 1 Turn the fuel valve clockwise to OFF to shut off the fuel supply 1 Turn the valve counter clockwise to ON to turn the fuel suppl...

Page 125: ...m contact with the skin eyes or clothing If contact occurs seek immediate medical attention KEEP OUT OF REACH OF CHILDREN EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Cal...

Page 126: ...positive battery cable second 5 Carefully lift the battery out of the snowmobile Do not tip it sideways or spill electrolyte Tap water contains minerals that will damage a battery and shorten its life...

Page 127: ...trap 2 Install the battery vent line It must be free from obstructions and securely installed Route the vent line properly to prevent kinks and to allow for proper drainage 3 Connect and tighten the r...

Page 128: ...case 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 Prem...

Page 129: ...if necessary SEE YOUR DEALER Harsh drive clutch engagement Drive belt worn or too narrow Replace drive belt engagement Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt...

Page 130: ...elt Inspect and replace if necessary performance Excessive belt sheave clearance SEE YOUR DEALER Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Engine doesn t start electric start...

Page 131: ...compression Running a mixture too lean too small main jet will cause seizure resulting in loss of power SEE YOUR DEALER This indi cates a major engine problem that must be repaired before engine is r...

Page 132: ...ight on skis Check hi fax and replace if worn Reduce ski pressure SIncrease front track spring preload SReduce IFS spring preload by adjusting threaded collar SReduce rear torsion spring preload Front...

Page 133: ...and grease all pivot points Adjust RCA rearward see setup decal under hood Decrease spring preload adjustments Decrease front track compression damping by turning screw counter clockwise factory posi...

Page 134: ...M Avoid riding in high ambient temperatures Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm...

Page 135: ...3 Dealer name 7 Previous correspondence 4 Date of purchase Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris C...

Page 136: ...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 ha...

Page 137: ...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 deal...

Page 138: ...cuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered con...

Page 139: ...tomatic with no additional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validat...

Page 140: ...ake 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 verific...

Page 141: ...and Linkage 119 Coolant Level 92 Coolant Mixture 92 Cooling 91 Coupler Greasing 80 D Daily Storage 72 Disabled Operators 12 Drive Belt 17 Drive Belt Adjustment 107 Drive Belt Deflection 107 Drive Belt...

Page 142: ...g Area 55 OPERATION 56 72 Operation 26 27 Operator Safety 8 21 P Passenger 23 PERC 71 Plug Cleaning 88 POLARIS PRODUCTS 126 Powder Snow Operation 19 PRE RIDE INSPECTIONS 51 55 Premium Fuel Switch 62 P...

Page 143: ...41 42 Suspension Rear ETS ACE 43 44 Suspension Rear WideTrak 45 Symbols 8 T TABLE OF CONTENTS 4 Taillight Replacement 103 THE PERFECT FIT 30 50 Throttle Cable 81 T Throttle Lever 67 Throttle Safety Sw...

Page 144: ...your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9918226 Rev 02 Printed in U...

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Polaris Touring 2004, Owner'S Manual

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Summary of Contents for Touring 2004

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