Polaris Trail Touring Deluxe Owner'S Manual Download Page 151

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148

INDEX

Accessories . . . . . . . . . . . . . . . . . . . 47

Air Pollution . . . . . . . . . . . . . . . . . . . 5

Airbox Warning . . . . . . . . . . . . . . . . 22

Avalanches. . . . . . . . . . . . . . . . . . . . 14

Battery . . . . . . . . . . . . . . . . . . . 124-127

Battery Connections. . . . . . . . . . . . 124

Battery Fluid . . . . . . . . . . . . . . . . . 124

Battery Installation. . . . . . . . . . . . . 126

Battery Storage . . . . . . . . . . . 123, 127

Bearings . . . . . . . . . . . . . . . . . . . . . 121

Bleeding the Brake System . . . . . . . 99

Brake Components. . . . . . . . . . . . . . 97

Brake Fluid . . . . . . . . . . . . . . . . . . . 98

Brake Inspection . . . . . . . . . . . . . . . 97

Brake Inspection, Hydraulic . . . . . . 97

Brake Lever Travel, Hydraulic . . . . 50

Brake Lever Travel, Mechanical . . . 51

Brake System Bleeding . . . . . . . . . . 99

Brakelight Replacement. . . . . . . . . 102

Brakes . . . . . . . . . . . . . . . . . . 50, 97-99

Carbide Skags . . . . . . . . . . . . . . . . . 45

Carburetion . . . . . . . . . . . . . . . . 64, 65

Carburetor . . . . . . . . . . . . . . . . . . 89-90

Carburetor Adjustments. . . . . . . . . . 89

Carburetor Protection. . . . . . . . 121-122

Cargo Overload . . . . . . . . . . . . . . . . 11

Cargo Rack . . . . . . . . . . . . . . . . . . . 29

Chain Tension . . . . . . . . . . . . . . . . 110

Chaincase Oil. . . . . . . . . . . . . . . . . . 84

Choke. . . . . . . . . . . . . . . . . . . . . . . . 56

Choke Cable Lubrication. . . . . . . . . 82

Choke Lubrication . . . . . . . . . . . . . . 82

Cleaning and Preservation . . . . . . . 120

Clutch Alignment Offset . . . . . . . . 104

Clutch and Drive System. . . . . . . . 121

Clutch Center Distance . . . . . . . . . 104

Clutch Cover Warning. . . . . . . . . . . 22

Clutch Guard . . . . . . . . . . . . . . . . . . 18

Clutch Safety . . . . . . . . . . . . . . . . . . 18

Clutch System . . . . . . . . . . . . . 103-109

Cold Weather Drive-Away . . . . . . . 18

Controls and Linkage. . . . . . . . . . . 120

Coolant. . . . . . . . . . . . . . . . . . . . . . . 92

Coolant Level. . . . . . . . . . . . . . . . . . 93

Cooling System, Bleeding . . . . . . . . 95

Cooling System, Flushing . . . . . . . . 94

Cooling System, WideTrak . . . . . 92-95

Coupler Greasing . . . . . . . . . . . . . . . 82

Coupling, Front To Rear . . . . . . . . . . 39

Coupling, Rear To Front . . . . . . . . . . 40

Coupling, Suspension . . . . . . . . . 39-40

Customer Service. . . . . . . . . . . . . . . 134

Deicers . . . . . . . . . . . . . . . . . . . . . . . . 62

Disabled Operators . . . . . . . . . . . . . . 11

Drive Belt . . . . . . . . . . . . . . . . . . . . . 17

Drive Belt Adjustment. . . . . . . . . . . 108

Drive Belt Condition . . . . . . . . . . . . 105

Drive Belt Deflection. . . . . . . . . . . . 108

Drive Belt Installation . . . . . . . . . . . 107

Drive Belt Removal . . . . . . . . . . . . . 106

Drive Chain Tension . . . . . . . . . . . . . 96

Driver Awareness . . . . . . . . . . . . . . . 13

Driveshaft Bearing Lubrication . . . . . 81

Driving Downhill. . . . . . . . . . . . . . . . 16

Driving in Hilly Terrain. . . . . . . . . . . 17

Driving on Slippery Surfaces . . . . . . 15

Driving Responsibly . . . . . . . . . . . . . 20

Electrical Connections. . . . . . . . . . . 123

Emission Control Information . . . 74-75

Engine Break-In. . . . . . . . . . . . . . 57-58

Engine Protection . . . . . . . . . . 121-122

Engine Safety. . . . . . . . . . . . . . . . . . . . 8

Engine Stop Switch . . . . . . . . . . . . . . 66

Environment . . . . . . . . . . . . . . . . . . . . 5

Exhaust System . . . . . . . . . . . . . . . . . 91

Exhaust System, Variable (VES). . . . 91

Filters, Intake . . . . . . . . . . . . . . . . . . . 87

FRSS . . . . . . . . . . . . . . . . . . . . . . . . . 39

Fuel . . . . . . . . . . . . . . . . . . . . . . . 60-62

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 88

Fuel Lines . . . . . . . . . . . . . . . . . . . . . 88

Fuel Reserve . . . . . . . . . . . . . . . . . . . 62

Fuel System Deicers . . . . . . . . . . . . . 62

Fuel Valve . . . . . . . . . . . . . . . . . . . . . 60

Gearcase Oil Level (WideTrak) . . . . 83

Handlebar Adjustment. . . . . . . . . . . . 43

Headlight Adjustment . . . . . . . . . . . 100

Headlight Bulb Replacement. . 101-102

High Temperature Indicator . . . . . . . 93

Hood Latches. . . . . . . . . . . . . . . . . . . 54

Summary of Contents for Trail Touring Deluxe

Page 1: ......

Page 2: ...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 9920449 Rev 02 Printed in U...

Page 3: ...ns 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 th...

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: ...f 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...

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 48 This sectio...

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

Page 8: ...orm 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: ...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 sno...

Page 12: ...eeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE...

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: ...own 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...

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: ...ack 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 oper...

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: ...proved 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 app...

Page 30: ...itch 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 Starte...

Page 31: ...ssenger Lumbar Adjuster 4 Windshield 5 Handlebar 6 Operator Seat 7 Passenger Seat 8 Taillights 9 Rear Bumper 10 Snow Flap 11 Passenger Grab Handle 12 Track 13 Suspension 14 Trailing Arm 15 Nosepan 16...

Page 32: ...port ing larger items 1 Remove the cargo bag 2 Push down on the seat latch lever at the lower rear of the passenger seat 3 Lift up the seat and remove it from the chassis 4 Reverse the procedure to re...

Page 33: ...nd then customizing each adjustment 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 spe...

Page 34: ...t 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 further...

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: ...and ensure that both sides are adjusted the same When decreasing preload make sure at least two turns of preload are holding the spring between the retainer on top of the shock and the threaded spring...

Page 37: ...pension designs and adjustments 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...

Page 38: ...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 39: ...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 measure ment Y...

Page 40: ...am 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 a guidel...

Page 41: ...alf 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 full turns...

Page 42: ...f 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 couples the...

Page 43: ...etween 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 in improv...

Page 44: ...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 transfer if desired Stock Position This setting is...

Page 45: ...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 46: ...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 handle bars brake lever and...

Page 47: ...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 48: ...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 49: ...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 50: ...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 51: ...teering System 53 Recoil Rope 54 Coolant Level 93 Parking Brake Lock Brake Lever Brake System 50 52 97 Auxiliary Shut Off Switch Engine Stop Switch 55 Ignition Switch 55 Taillight Brakelight Headlight...

Page 52: ...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 53: ...e indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding information on page 99 or see your dealer for service NOTE If the brake lever feels spongy when squeezed ch...

Page 54: ...ms for proper operation before starting the engine Brake Lever Travel Firmly depress the brake lever Measure the distance between the lever and brake block The distance should be no more than 3 4I 1 9...

Page 55: ...ill move freely into place Do not force the lock or it may break The brake light on the console will light up if the parking brake lever lock is set while the engine is running It will also be lit whe...

Page 56: ...r 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 coul...

Page 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...e across the country so we encourage the use of premium fuel when possible Do not use fuel containing more than 10 ethanol including E85 NOTE Some engines require premium fuel See your Owner s Manual...

Page 65: ...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 66: ...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 67: ...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 68: ...main jet installed in production is not correct for all altitudes and or temperatures See page 89 for more information NOTE It s the owner s responsibility to ensure that the correct jets are install...

Page 69: ...eration 1 Sit on the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pres sure on the pivot pin in the direction shown in the illustration 4 Apply a s...

Page 70: ...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 71: ...he engine stop switch and throttle safety switch SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Choke Floods engine Half throttle or l...

Page 72: ...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 73: ...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 74: ...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 75: ...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 76: ...rate 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 o...

Page 77: ...should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision E...

Page 78: ...prior to each use including the airbox foam filter and hood foam filters and clean these components as necessary Polaris considers the specified maintenance for the spark plugs oil changes air intake...

Page 79: ...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 80: ...00 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 104 I I I Drive Belt Condition 105 I I I I Clutches disassemble 103 C C C Belt Tension I I I I Clutch Sheaves 103 I I I I E...

Page 81: ...ews I I I Carburetor synchronize 89 I I I Idle RPM I I I Throttle Lever 67 I I I I I Oil Pump Lever synchronize I I I Throttle Cable 82 L L L Choke Cable 82 L L L Choke 82 I I I Vent Lines I I I I Thr...

Page 82: ...rings 121 L L L I Skags Wear Bars 117 I I I I I Ski Saddle Spindle Bolts I I I I I Ski Pivots 80 L L L L I Ski Spindle 80 L L L L I Steering Arm s I Upper Lower Steering Post Support Bracket 80 L L L...

Page 83: ...128 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 84: ...ion WideTrak Rear Suspension Driveshaft Bearing Inject grease into the fitting on the speedome ter sensor housing until grease purges from the seal on the inside of the tunnel This should take approxi...

Page 85: ...ning bolt Torque to 18 ft lbs 24 4 Nm Coupler Greasing WideTrak Grease the couplers on the driveshaft and jackshaft Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engi...

Page 86: ...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 87: ...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 128 f...

Page 88: ...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 Supplement or se...

Page 89: ...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 excessive oil use of non recommended...

Page 90: ...am 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 removed ma...

Page 91: ...ers are specially designed for use on Polaris products We strongly recommend the use of only Polaris replacement parts See page 58 for oil recommendations EDGE models use an oil filter that s built in...

Page 92: ...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 carburetor may...

Page 93: ...n 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 reinsta...

Page 94: ...ng 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 performance an...

Page 95: ...protection under most conditions If the vehicle will be stored or oper ated at extremely low temperatures greater protection may be required Please see your Polaris dealer When adding or changing cool...

Page 96: ...ine coolant level is controlled by the recovery system The recovery system components are Coolant bottle or overflow tank Engine filler neck Pressure cap on some models Connecting hoses The coolant le...

Page 97: ...intains its ability to protect the engine drain the system completely every two years and add a fresh mixture of antifreeze and distilled water This service must be performed when the engine is cold A...

Page 98: ...ttle 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 4 I...

Page 99: ...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 2 until it...

Page 100: ...essive 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 when thi...

Page 101: ...years with Polaris DOT 4 high temperature brake fluid See page 128 for the part numbers of Polaris products WARNING After opening a bottle of brake fluid always discard any unused portion Never store...

Page 102: ...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...

Page 103: ...e 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 ai...

Page 104: ...Lift the spring carefully around the wire harness 2 and flip it to the outside of the housing 3 With the wire harness attached to the bulb 3 withdraw the bulb from the housing 4 Grasp the bulb by its...

Page 105: ...d replace with new bulb 4 Place the bulb and housing back inside the hole and turn the housing 1 2 turn clockwise to lock into place 5 Reinstall the wire harness to the housing Taillight Brakelight Re...

Page 106: ...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 Polaris de...

Page 107: ...eave width of the drive clutch For this reason Polaris rec ommends that only O E M belts be used Other belts may match the dimensions but can drastically change the shift pattern resulting in poor per...

Page 108: ...r frayed edges missing cogs cracks and excessive looseness Replace the belt if any of these conditions exist See Belt Troubleshooting on page 133 For improved drive away during extremely cold temperat...

Page 109: ...ch 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 to...

Page 110: ...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 the...

Page 111: ...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 the s...

Page 112: ...ially impor tant to maintain track tension as specified on page 112 Allow the engine to reach idle speed before attempting to shift into or out of reverse WARNING Improper track tension can cause seri...

Page 113: ...imum performance arrange 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 in...

Page 114: ...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 lubrication...

Page 115: ...cified distance see chart ahead of the center of the rear idler wheel NOTE Measure at the point where the weight is hanging WARNING Moving parts can cut and crush body parts When performing the checks...

Page 116: ...l adjustment on both sides of the track 8 Repeat the measure ment on the other side of the track NOTE Check more fre quently when the machine is new 9 Start the machine and slowly rotate the track at...

Page 117: ...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 runs t...

Page 118: ...115 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 119: ...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 120: ...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 121: ...ve a wear limit indicator groove to indicate the minimum permissible slide thickness Replace the rail slides if they are worn to the top of the groove at any point along their length Failure to do so...

Page 122: ...unting bolts for tightness NOTE To check the Touring rear suspen sion mounting bolts remove the access plugs in the skirt n Check rear idler wheel bolts for tight ness See page 113 n Check rear idler...

Page 123: ...rfaces 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 surfaces before beginning preservation with waxe...

Page 124: ...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 125: ...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 126: ...rts and hot exhaust parts Battery Always prepare and maintain the battery as outlined on page 127 Track and Suspension Moderate track tension should be maintained during summer storage The machine sho...

Page 127: ...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 128: ...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 129: ...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 130: ...e 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 recharging Batteries may freeze if not fully charged r...

Page 131: ...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 132: ...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 133: ...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 134: ...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 135: ...rail slide and replace if worn 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 f...

Page 136: ...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 137: ...n tained in this manual Your dealer is also familiar with Polaris policies and pro cedures and will be happy to assist you When contacting us about parts service or warranty always provide the fol low...

Page 138: ...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 139: ...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 140: ...t 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 deale...

Page 141: ...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 142: ...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 143: ...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 144: ...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 145: ...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 ment...

Page 146: ...udes compo nents whose failure increases the snowmobile engine s emissions To the extent they are present on your snowmobile engine this includes electronic controls fuel injection components exhaust...

Page 147: ...es beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris can deny an emissions warranty claim if any specified critical...

Page 148: ...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 149: ...146 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 150: ...147 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 151: ...and Linkage 120 Coolant 92 Coolant Level 93 Cooling System Bleeding 95 Cooling System Flushing 94 Cooling System WideTrak 92 95 Coupler Greasing 82 C Coupling Front To Rear 39 Coupling Rear To Front...

Page 152: ...ock Spring 33 Pre Ride Checklist 48 Pre Ride Suspension Inspection 119 Pressure Cap Warning 22 R Rail Slide Wear 118 Recoil Rope 54 Registration Warranty 136 Reverse Maintenance 109 Reverse Operation...

Page 153: ...sion Rear Spring 37 Throttle Cable Lubrication 82 Throttle Lever 49 67 Throttle Safety Switch 49 66 Tool Kit 110 T Torque Stop 109 Towing 73 Track 53 111 114 Track Alignment 114 Track Care for Storage...

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Polaris Trail Touring Deluxe, Owner'S Manual

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