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Polaris Trail Touring 2006, Owner'S Manual, Page: 127 / 159

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Polaris Trail Touring 2006 Owner'S Manual Download Page 127

124

MAINTENANCE

Steering System

n

Rail Slide Wear

Measure slide thickness at sev-

eral points along the rail.  Have 

your dealer replace the slide 

when it's worn down to the mini-

mum thickness. Do not operate 

the snowmobile if slide thickness 

measures less.

   7/16

I

(1.1 cm)

  3/8

I

(1 cm)

Minimum Thickness

All Except WideTrak

Minimum Thickness

WideTrak

Summary of Contents for Trail Touring 2006

Page 1: ......

Page 2: ......

Page 3: ...RNING Snowmobile engines discharge fuel and exhaust which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm onto the snow on which they op...

Page 4: ...velopment of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner...

Page 5: ...ion 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 refe...

Page 6: ...of your snowmobile s controls and features The Perfect Fit 30 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 53 This sectio...

Page 7: ...______________________________________ right front side of engine crankcase Key Number ___________________________________________________________ Important Notes for Owners and Drivers After reading...

Page 8: ...rm 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 removed The sound...

Page 9: ...t symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The s...

Page 10: ...obile 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 u...

Page 11: ...k its operation WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the sn...

Page 12: ...shifting ability This could affect your ability to control this rider active vehicle in cer tain extreme driving situations Riding Apparel Be prepared be warm and be com fortable when riding Be aware...

Page 13: ...ival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a...

Page 14: ...ome Polaris snowmobiles are designed for up to two riders A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only See page 23 for decal locat...

Page 15: ...look back for only two sec onds your machine will travel about 120 feet If your speed is 60 MPH your machine will travel about 180 feet in two seconds Traveling at night requires extra caution Check h...

Page 16: ...wn out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or high ways Steep embankments may also hide your view Always leave yourself a w...

Page 17: ...lope 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 moun tain...

Page 18: ...age Driving on Slippery Surfaces WARNING Ice and snow build up may interfere with the steering of your machine result ing in serious injury or death Keep the underhood area free of snow and ice WARNIN...

Page 19: ...to help slow the machine and keep it from rolling freely downhill WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may res...

Page 20: ...engine and set the parking brake if equipped Keeping away from the downhill side of the machine pull the rear of the snowmobile around and point the front end and skis downhill Remount the machine re...

Page 21: ...ondition 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 attemptin...

Page 22: ...and damage to the slide rail 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...

Page 23: ...or s certificate For their protection as well as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile Jumping may injure your back becau...

Page 24: ...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 mi...

Page 25: ...t 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 engine with hood open Do not attempt adjustment with engine...

Page 26: ...or a fall from seat back can result in severe injury or death Passenger Warning Polaris touring models and the WideTrak are designed for the operator and one passenger For more information on operatin...

Page 27: ...decal is located above the instrument housing WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind b...

Page 28: ...hile backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly For more information see Owner s Manual If electric reverse Machine stopped and engine at idle push y...

Page 29: ...ed 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 approve...

Page 30: ...witch 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 Hold Down Straps 12 Recoil Start...

Page 31: ...28 FEATURES 2 1 6 9 4 5 7 8 10 11 13 17 19 14 15 12 16 18 20 HIGH OFF LOW 3...

Page 32: ...shield 5 Handlebar 6 Operator Seat 7 Passenger Seat 8 Trunk Cover 9 Taillights 10 Rear Bumper 11 Snow Flap 12 Passenger Grab Handle 13 Track 14 Suspension 15 Trailing Arm 16 Nosepan 17 Front Bumper 18...

Page 33: ...justment individually to suit rider preference The machine should be methodically tested one change at a time under the same conditions trail and snow conditions vehicle speed riding position etc afte...

Page 34: ...at was used dur ing the ride If the travel is full the bumper will be seated at the top of the rod Shock Components The front springs can be changed if spring preload alone isn t sufficient and furthe...

Page 35: ...first The factory setting for this shock is the softest position with the adjusting screw all the way out counterclock wise If bottoming occurs the Indy Select feature should be used to achieve the de...

Page 36: ...the handling of the snowmobile and the performance of the suspension Never exceed one inch of preload beyond the factory settings and ensure that both sides are adjusted the same When decreasing prel...

Page 37: ...if spring preload alone isn t sufficient and fur ther adjustment is desired to control suspension stiffness See your Polaris dealer for more information WARNING Changing shock valving on RydeFX shock...

Page 38: ...nts involve a compromise or trade off For example a suspension set up for snowcross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bot tom out harshly o...

Page 39: ...p speed When riding on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are available from your dealer Polaris offers track kits...

Page 40: ...r seated measure the distance between the ground and the rear bumper at the exact location used for measurement X This is mea surement Y To determine sag commonly referred to as ride in subtract measu...

Page 41: ...osition cam using the engine spark plug tool Different rate torsion springs are available if a firmer ride is desired See your dealer for more information The following information is provided only as...

Page 42: ...ock In half turn increments turn the screw clockwise to increase compression valving and stiffen the ride or counterclockwise to reduce compression and soften the ride There are approximately three fu...

Page 43: ...ovement 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 rear scissor stop FRSS cou...

Page 44: ...vement 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 to transfer to the rear resulting i...

Page 45: ...in your tool kit To increase weight transfer or ski lift during acceleration move the RRSS to the rearward hole on high posi tion The RRSS may also be rotated to a lower position for even more weight...

Page 46: ...ront Track Spring and Preload Front track spring and preload can also be adjusted Turn the screw clockwise to tighten compression stiffen Turn the spring clockwise to tighten preload Initial Setup Ref...

Page 47: ...just loosen the hex bolts attaching the rear lower shock cross shaft to the rail beam See illustration 3 Using a 9 16 wrench loosen the jam nuts on the preload bolts 4 Adjust the preload bolts to the...

Page 48: ...Adjustments Front Arm Mounting Holes There are also two front arm mounting holes in the slide rail that can adjust ski pressure The lower hole increases ski pressure while the upper hole decreases sk...

Page 49: ...round and the same spot on the running board The difference between the two measurements should be approximately 1 1 2 3 8 cm If the difference is greater than 1 1 2 the rear spring should be adjusted...

Page 50: ...juster block turn handlebar to left or right for access to back nuts NOTE If necessary pry the blocks apart with a screwdriver 3 Adjust the handlebar to the desired height Be sure handlebars brake lev...

Page 51: ...can be adjusted 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 positions on the grab handle tub...

Page 52: ...mobile 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 fo...

Page 53: ...s still required on such surfaces Steering abil ity may be reduced on hard packed snow or ice When studded tracks are used increased wear to the brake pads will result from increased braking Extended...

Page 54: ...Maintain 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 char...

Page 55: ...trips or wear strip coolers installed Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction accessories Components viewed from rear of track 1 T...

Page 56: ...Steering System 57 Recoil Rope 58 Coolant Level 99 Park Brake Lock Brake Lever Brake System 55 56 103 Auxiliary Shut Off Switch Engine Stop Switch 59 Ignition Switch 59 Taillight Brakelight Headlight...

Page 57: ...ver to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not func tion smoothly or i...

Page 58: ...spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 104 n Mechanical Brakes Always check the following items for proper operation before starting the engine Br...

Page 59: ...will move freely into place Do not force the lock or it may break The brake light on the console will light up if the park brake lever lock is set while the engine is running It will also be lit when...

Page 60: ...ur machine result ing in serious injury or death Keep the underhood area free of snow and ice WARNING Operating the snowmobile with a damaged track increases the possibility of track failure which cou...

Page 61: ...d that the latches are securely in place before operating the snowmo bile n Seat Latches If your snowmobile is equipped with a removable seat ensure that the seat latches are securely in place before...

Page 62: ...n Tether Switch If your machine has a tether switch remove the tether from the switch to make sure the engine stops immediately n Lighting Check the headlight high and low beam taillight and brake li...

Page 63: ...crank the engine 7 Repeat the cranking procedure as needed until the engine starts 8 After the engine starts flip the choke toggle to the OFF position If the engine slows or wants to stop use intermi...

Page 64: ...ree 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 open ings and mac...

Page 65: ...e sludge formation filter blockage and reduced cold weather flow rates All Polaris oils are compatible with each other Slide Rail and Track Cooling CAUTION Serious engine damage can occur without the...

Page 66: ...es shut off the engine and lower the machine to the ground 5 Grasp the skis by their front loops and move them from side to side to loosen snow and ice WARNING A loose track or flying debris could cau...

Page 67: ...not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and...

Page 68: ...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 octane Return the key switch to the O...

Page 69: ...8 16 ml per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol Polaris also recommends the use of Ca...

Page 70: ...important when the machine is operated in mountainous ter rain Always check the oil level when refueling Maintain the oil level above the tank s low level line When the oil reaches the low level mark...

Page 71: ...e performance A lean mixture may be caused by things like fuel line restrictions for eign matter in the carburetor or clogged fuel filters A rich mixture may be caused by snow build up on the pre filt...

Page 72: ...ge The main jet installed in production is not correct for all altitudes and or tempera tures See page 95 for more information NOTE It s the owner s responsibility to ensure that the correct jets are...

Page 73: ...eration 1 Sit on the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration 4 Apply a sl...

Page 74: ...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 and...

Page 75: ...chassis 4 Reverse the procedure to reinstall the seat and trunk cover Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 70 for mor...

Page 76: ...te clock wise slightly to relieve belt tension 4 Starting at one of the tower struts wind the strap counter clockwise around the clutch as shown 5 Pull the strap abruptly so the strap comes free of th...

Page 77: ...hich gear is engaged Sometimes the drive belt will drag in the drive clutch causing slight tension in the transmission and making it hard to shift Shutting the engine off will remove this tension and...

Page 78: ...p the snowmobile and leave the engine idling 2 Make sure the area behind your vehicle is clear 3 Push the yellow reverse button on the left hand control for one sec ond then release The engine will au...

Page 79: ...machine is in forward Altitude Setting At higher altitudes above 6000 feet the engine will require a different ignition setting to improve the success of the reverse system To set for a higher altitud...

Page 80: ...erate the brake and steering when necessary WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury...

Page 81: ...owmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmob...

Page 82: ...our snowmobile prior to each use including the airbox foam filter and hood foam filters and clean these components as necessary Polaris considers the specified maintenance for the spark plugs oil chan...

Page 83: ...rvals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty perio...

Page 84: ...00 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 110 I I I Drive Belt Condition 111 I I I I Clutches disassemble 109 C C C Belt Tension I I I I Clutch Sheaves 109 I I I I E...

Page 85: ...crews I I I Carburetor synchronize 95 I I I Idle RPM I I I Throttle Lever 71 I I I I I Oil Pump Lever synchronize I I I Throttle Cable 88 L L L Choke Cable 88 L L L Choke 88 I I I Vent Lines I I I I T...

Page 86: ...rings 127 L L L I Skags Wear Bars 123 I I I I I Ski Saddle Spindle Bolts I I I I I Ski Pivots 84 L L L L I Ski Spindle 84 L L L L I Steering Arm s I Upper Lower Steering Post Support Bracket 84 L L L...

Page 87: ...134 for the part numbers of Polaris products The illustration shows the lubrication points of suspension and steering components Grease the left and right spindles Raise the front end of the machine...

Page 88: ...85 MAINTENANCE Lubrication EDGE 136 Rear Suspension Indy 340 Touring Edge Touring Rear Suspension...

Page 89: ...86 MAINTENANCE Lubrication WideTrak Rear Suspensions...

Page 90: ...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 Inject grease into the fitting on the speedometer...

Page 91: ...turn the handlebars to the left and lubricate liberally as shown Choke and Choke Cable Lubricate the choke slide and cables lightly with oil or grease Before turning the engine off operate the choke i...

Page 92: ...oil level place the machine on a level surface The oil level should be between the safe marks on the dipstick 1 See your Polaris dealer for the recommended oil for your machine Do not overfill NOTE Cl...

Page 93: ...oil level between the safe marks on the dipstick Clean the magnetic plug on the dipstick whenever checking or changing oil Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 134 f...

Page 94: ...ten cause a spark plug to appear too dark or too light in color Before changing spark plug heat ranges be sure the correct main jet is installed in the carbure tor s Refer to the Owner s Manual Supple...

Page 95: ...justments 2 Wet Fouled 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...

Page 96: ...of the foam filter periodically to remove any accumulation of snow NOTE These illustrations are general representations Your model may differ CAUTION Operating the snowmobile with the intake filters...

Page 97: ...s oil filters are specially designed for use on Polaris products We strongly recommend the use of only Polaris replacement parts See page 62 for oil recommendations EDGE models use an oil filter that...

Page 98: ...nchronized 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 carb...

Page 99: ...sition 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 and re...

Page 100: ...and cleaning of system components Every 1000 to 2000 miles 800 1600 km bring the machine to an authorized Polaris dealer to have the VES disassem bled inspected and cleaned NOTE To ensure maximum perf...

Page 101: ...e cap Heat exchangers Coolant Use Premium 60 40 anti freeze coolant which is already premixed and ready to use Do not dilute with water Never exceed a 60 antifreeze 40 water mixture Contact your deale...

Page 102: ...hoses The coolant level in the coolant bottle must be maintained at the recom mended level shown on the coolant bottle to prevent overheating and serious engine damage The level on some models must b...

Page 103: ...bottle with coolant to the maximum mark 2 Elevate the front end of the machine slightly to aid bleeding of the heat exchangers 3 Remove the pressure cap and add coolant to the top of the filler neck...

Page 104: ...4 Add coolant to the coolant 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 engin...

Page 105: ...ockwise to move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut 1 3 Finger tighten the adjuster bolt...

Page 106: ...if excessive brake pad clearance develops bring the machine to an authorized Polaris dealer for inspec tion and adjustment Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace w...

Page 107: ...ry two years with Polaris DOT 3 high temperature brake fluid See page 134 for the part numbers of Polaris products WARNING After opening a bottle of brake fluid always discard any unused portion Never...

Page 108: ...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...

Page 109: ...r to the 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 shoul...

Page 110: ...bulb from the housing 4 Grasp the bulb by its metal base and carefully separate the bulb from the harness 5 Hold the new bulb by its metal base and install it into the wire har ness 6 Insert the bulb...

Page 111: ...rakelight Replacement 1 Remove the rear storage cover 1 if equipped 2 Depending on your model remove the screws 2 securing either the taillight housing 3 or the lens cover 4 3 Remove and replace the b...

Page 112: ...ment or an unusual vibration or shift pattern see your dealer immediately Do not operate the machine until repairs have been made All clutch maintenance and repairs must be performed by an authorized...

Page 113: ...sheave width of the drive clutch For this reason Polaris recommends that only O E M belts be used Other belts may match the dimensions but can drastically change the shift pat tern resulting in poor p...

Page 114: ...wear frayed edges missing cogs cracks and excessive looseness Replace the belt if any of these conditions exist See Belt Troubleshooting on page 140 For improved drive away during extremely cold tempe...

Page 115: ...lutch Skip to step 8 7 TEAM Clutch Locate the L wrench in the tool kit and install it into the open threaded hole in the outer sheave of the clutch Rotate the wrench until the sheaves open far enough...

Page 116: ...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...

Page 117: ...rom the jackshaft 1 Pull the belt into the driven clutch to slightly open the sheaves 2 Loosen the three bolts on the adjustment cam and turn the cam counterclockwise to reduce the distance between th...

Page 118: ...pecially impor tant to maintain track tension as specified on page 118 Allow the engine to reach idle speed before attempting to shift into or out of reverse WARNING Improper track tension can cause s...

Page 119: ...e for a fall service tune up with your Polaris dealer His experienced and trained service technician will keep your machine in peak operating condition Tool Kit A tool kit is included with each machin...

Page 120: ...slide 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 ice or under other poor lubri...

Page 121: ...nter of the rear idler wheel NOTE Measure at the point where the weight is hanging WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the follo...

Page 122: ...vide equal adjustment on both sides of the track 8 Repeat the mea surement on the other side of the track NOTE Check more frequently when the machine is new 9 Start the machine and slowly rotate the t...

Page 123: ...s Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track...

Page 124: ...121 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary WideTrak EDGE IFS...

Page 125: ...at point X should be 1 8I to 1 4I 3 6 mm greater than the measurement at point Y NOTE If the skis are misaligned we recommend that your dealer cor rect the alignment since camber adjustment may also...

Page 126: ...I 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the rear end of the skag 4 Remove the front end of the skag 5 Reverse the steps to install a skag WARNING Worn...

Page 127: ...ess at sev eral points along the rail Have your dealer replace the slide when it s worn down to the mini mum thickness Do not operate the snowmobile if slide thickness measures less 7 16I 1 1 cm 3 8I...

Page 128: ...ng bolts for tightness NOTE To check the Indy 340 Touring rear suspension mounting bolts remove the access plugs in the skirt n Check rear idler wheel bolts for tightness See page 119 n Check rear idl...

Page 129: ...faces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be sure that corrosive salt and acids are removed from sur faces before beginning preservation with waxe...

Page 130: ...Master Repair Manual See your dealer Engine and Carburetor Protection Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine parts durin...

Page 131: ...storage 2 Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward 3 Remove the spark plug s 4 Rotate the engine slowly watching the...

Page 132: ...rts and hot exhaust parts Battery Always prepare and maintain the battery as outlined on page 133 Track and Suspension Moderate track tension should be maintained during summer storage The machine sho...

Page 133: ...y WARNING Battery electrolyte is poisonous It contains acid Serious burns can result from contact with the skin eyes or clothing If contact occurs seek immedi ate medical attention KEEP OUT OF REACH O...

Page 134: ...not tip it side ways or spill electrolyte WARNING Improperly connecting or disconnecting battery cables can result in an explo sion and cause serious injury or death When removing the battery always d...

Page 135: ...ive cable first 4 Connect and tighten the black negative cable last 5 Verify that cables and vent hose are properly routed WARNING Batteries contain gases that can explode If the battery vent tube is...

Page 136: ...it to the proper level Store it in a cool dry place Check and or charge monthly Before using the battery take it to your dealer for testing and recharg ing Batteries may freeze if not fully charged r...

Page 137: ...3 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...

Page 138: ...sary SEE YOUR DEALER Harsh drive clutch engagement Drive belt worn or too narrow Replace the drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for appli catio...

Page 139: ...ve clearance SEE YOUR DEALER Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Engine doesn t turn Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fu...

Page 140: ...ne several times may be necessary to change plug s Poor engine com pression Mixture is too lean A main jet that is too small will cause seizure resulting in loss of power This indicates a major engine...

Page 141: ...n Reduce ski pressure A Increase front track spring preload B Reduce IFS spring preload C Reduce rear torsion spring preload Front end pushes Check for worn skags Check for binding suspension shafts a...

Page 142: ...RCA rearward see setup decal under hood Decrease spring preload adjustments Decrease front track compression damping by turning screw counter clockwise factory position full soft Machine darts from si...

Page 143: ...atures Check for snow ingestion 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 it up Break...

Page 144: ...ontained 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 fol lowi...

Page 145: ...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 mode...

Page 146: ...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...

Page 147: ...t present your copy of the Warranty Registration form to the dealer The cost of trans portation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling deal...

Page 148: ...verage 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 he...

Page 149: ...tomatic Although you do not receive a warranty card your dealership should have printed a copy of the warranty reg istration form This form is your proof of warranty Consumer Exclusions Each repair vi...

Page 150: ...e to unauthorized service Failures due to lack of service as required in the owner s manual or Polaris updates This includes off season storage as listed in the owner s manual Failure due to use of un...

Page 151: ...have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bu...

Page 152: ...s Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu men...

Page 153: ...nty This includes compo nents whose failure increases the snowmobile engine s emissions To the extent they are present on your snowmobile engine this includes electronic controls fuel injection compon...

Page 154: ...r similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris can deny an emissions warranty claim if any spec...

Page 155: ...r 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...

Page 156: ...153 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 157: ...Coolant 98 Coolant Level 99 Cooling System 98 Cooling System Bleeding 100 101 Cooling System Flushing 99 Coupler Greasing 87 Coupling Front To Rear 40 C Coupling Rear To Front 41 Coupling Suspension...

Page 158: ...l Recommendations 62 O Oil Gearcase WideTrak 89 Operation Warning 26 Operator Safety 6 21 P Park Brake Lever Lock 56 Passenger Warning 23 Polaris Products 134 Preload Front Shock Spring 33 Premium Fue...

Page 159: ...Engine Stop 27 59 70 Handwarmer 27 Headlight Dimmer 27 Heater Passenger Handle 29 Ignition 27 59 Premium Fuel 65 Tether 59 Throttle Safety 54 70 Thumbwarmer 27 T Taillight Brakelight Replacement 108...

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