Polaris turbo iq Page 103 Owner'S Manual Download

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100

MAINTENANCE

Gearcase Oil

Gearcase Oil Check

Check and change the gearcase oil at

the intervals outlined in the Periodic

Maintenance Table beginning on page

87.
Polaris recommends the use of Polaris

Synthetic Chaincase Lube. See page

135 for the part numbers of Polaris

products.
The dipstick is located on the lower

front side of the gearcase. Maintain

the oil level in the safe operating

range, between the upper and lower

marks on the dipstick.
1. Position the vehicle on a level

surface.

2. Remove the dipstick and wipe it

dry with a clean cloth. Reinstall

the dipstick.

3. Remove the dipstick and view the oil level.
4. Add the recommended oil as needed. Do not overfill.
5. Reinstall the dipstick.

Dipstick

SAFE Range

Summary of Contents for turbo iq

Page 1: ......

Page 2: ...r your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922293 Rev 01 Printed in USA Pantone 425...

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: ...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 5: ...ements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedure...

Page 6: ...of your snowmobile s controls and features The Perfect Fit 50 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 64 This sectio...

Page 7: ...4...

Page 8: ...are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary t...

Page 9: ...f our environment Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that...

Page 10: ...ris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number ___________________________________________________ Tunnel VIN _________...

Page 11: ...eir meanings before reading the manual The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death o...

Page 12: ...is in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used a...

Page 13: ...ehind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures Stay Clear of...

Page 14: ...ride in a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always c...

Page 15: ...will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterpro...

Page 16: ...r snowmobile Snowmobiles designed for two riders should never be operated with more than two people on board When traveling with a passenger it s the driver s responsibility to operate the snowmobile...

Page 17: ...mobile will travel about 120 feet 36 m If your speed is 60 MPH 96 km h your snowmobile will travel about 180 feet 55 m in two seconds Traveling at night requires extra caution Check headlight and tail...

Page 18: ...difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your snowmobile will drown out the sound of approaching vehicles Look ahead beh...

Page 19: ...now is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow c...

Page 20: ...ous injury or death Keep the underhood area free of snow and ice Driving Downhill When riding downhill shift your weight to the rear of the snowmobile and reduce your speed to a minimum Apply just eno...

Page 21: ...ating in hilly terrain If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper...

Page 22: ...peeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has...

Page 23: ...rail and track causing premature wear damage and failure which can result in serious injury Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rai...

Page 24: ...as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of sp...

Page 25: ...93 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min 5 min...

Page 26: ...replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Clutch Cover Warning This warning decal is found under the hood on the clutch cover W...

Page 27: ...ehicle is designed for operator and ONE passenger only Hot Surface Warning The hot surface warning is located near the rear of the tunnel on applicable models WARNING HOT SURFACE DO NOT TOUCH Burn may...

Page 28: ...avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If...

Page 29: ...wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age require ments When operating with a passe...

Page 30: ...dragging the snow mobile 3 Hood 4 Headlight 5 Windshield 6 Handlebar 7 Mirrors if equipped 8 Fuel Filler Cap 9 Operator Seat 10 Cargo Bag if equipped 11 Taillights 12 Rear Bumper 13 Snow Flap 14 Trac...

Page 31: ...ever 5 MFD Multi Function Display 6 Engine Stop Switch 7 Throttle Control 8 Hood Hold Down Straps 9 Parking Brake 10 Handlebar Grip Warmer Switch 11 Thumbwarmer Switch 12 Electronic Reverse Button 13...

Page 32: ...ceed the rack weight limit Do not allow a passenger to sit on the seat back or the cargo rack Adjustable Headlights Move the adjuster to the left to lower the headlight beam Move the adjuster to the r...

Page 33: ...ustability Removing this lockout and using RIDER SELECT position 6 or 7 will result in the handlebars and brake lever contacting other components and interfering with steering and braking This could l...

Page 34: ...ail Riding Boondocking Deep Snow Riding Rider weight is centered on the snowmo bile providing balance comfort and con trol for both novice and experienced riders This is the recommended position for m...

Page 35: ...Do not lubricate the RIDER SELECT mechanism Doing so could cause loss of control and result in serious injury or death The RIDER SELECT mechanism is lubricated for life at the factory WARNING Some aft...

Page 36: ...se of a flashing MIL or high temperature indicator serious engine damage may occur with continued operation See your Polaris dealer 1 Verify that all electrical connections are secure 2 Check battery...

Page 37: ...selected speed sensor error Reverse 5300 Engine will mis fire at higher engine speed Defective rollover switch speed sensor error Rollover 6000 Throttle stuck throttle lever depressed speed sensor err...

Page 38: ...stutter If you do not notice the flashing indicator on the MFD or do not suffi ciently cool the snowmobile the engine will misfire to alert you to look at the MFD and take action Again driving the sn...

Page 39: ...the system senses detonation beyond a preset limit it retards ignition timing and adds fuel to reduce the detonation and prevent engine damage When the detonation returns to a permissible level the s...

Page 40: ...h Beam Indicator Item 1 RPM or Speed Altitude if equipped Service Interval 2 Electrical System Voltage Level 3 MAX Maximum MPH KPH or RPM MPH Miles per hour KPH Kilometers per hour RPM Engine cranksha...

Page 41: ...g or with the engine off If the engine is off make sure the stop switch is pressed down and turn the ignition key to the START position briefly to activate the gauge The gauge will illuminate for abou...

Page 42: ...display the tachometer option 1 If the analog is set to show the tachometer the digital screen will show the speedometer option 2 To change viewing preferences press and hold the MODE button for three...

Page 43: ...See page 39 Press and release the SET button to cycle through the following screens odometer trip 1 odometer trip 2 odometer fuel trip odometer if fuel is low and clock if equipped Use the following...

Page 44: ...ped with an electronic fuel gauge The fuel symbol and the last fuel bar on the MFD gauge if equipped will blink when the fuel level reaches 1 8 of a tank The Trip F odometer records distance traveled...

Page 45: ...seconds 4 When the hour starts flashing press the SET switch once to advance one hour Press and hold the SET button to advance the hours quickly 5 Press and release the MODE button to save the hour T...

Page 46: ...he following screens hour meter engine temperature air temperature available as an acces sory altimeter available as an accessory and turbo boost Hour Meter The hour meter records the total hours of e...

Page 47: ...vance quickly by 100 foot 30 m incre ments 5 Adjust the altitude display to within 50 ft 15 m of current altitude Tip The gauge reads barometric pressure and allows the rider to compensate for daily f...

Page 48: ...Maximum RPM The gauge automatically logs the maximum speed and engine RPM even if the history program is not active in the display 1 Enter the History Program 2 Press and release the SET button until...

Page 49: ...dometer area and ENG will flash in the icon area for five seconds each time the engine is started until the service reminder is reset Use the following procedures to reset the reminder To reset the re...

Page 50: ...active 3 Press and hold the SET button for five seconds until the hours begin to flash Immediately release the button 4 Press the button again up to five times to advance the reminder in 50 hour incr...

Page 51: ...y compart ment It has a red wire and a brown wire with a white stripe It s located about three inches down the main harness from the point where the harness connects to the MFD 3 Cut the plastic cable...

Page 52: ...ake sure the taped seam of the compartment faces the downward side of the wire harness 9 Install a cable tie to secure the compartment to the wire harness in the same location where the previous cable...

Page 53: ...ttings and then customizing each adjustment individually to suit rider preference The snowmobile should be methodically tested one change at a time under the same conditions trail and snow condi tions...

Page 54: ...e factory settings and ensure that both sides are adjusted the same When decreasing preload make sure at least two turns of preload are hold ing the spring between the retainer on the top of the shock...

Page 55: ...iffer ride Turn the knob counterclockwise B for a softer ride Shock Valving Some shocks can be revalved if spring preload or compression adjust ments aren t sufficient and further adjustment is desire...

Page 56: ...ay vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride In deep...

Page 57: ...ce up and down several times collapsing the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact location used for measure ment X This is meas...

Page 58: ...irmer ride is desired See your dealer for more information Limiter Strap Position Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling If a rider pr...

Page 59: ...the adjustment knob on the shock reservoir to make adjustments to the compression damping Positions are labeled on the shock When adjusting we recommend that you turn the adjuster slightly then test r...

Page 60: ...uspension coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amo...

Page 61: ...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 performance An adj...

Page 62: ...for most trail riding conditions To decrease weight transfer under acceleration for improved corner ing rotate the RRSS to a higher position To increase weight transfer or ski lift during acceleration...

Page 63: ...ts on the bottom of the adjuster block turn han dlebar to left or right for access to back nuts Tip If necessary pry the blocks apart with a screwdriver 3 Adjust the handlebar to the desired height Be...

Page 64: ...nowmobile 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...

Page 65: ...ack of clearance between upper carrier wheels and track Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tu...

Page 66: ...tain a proper balance between the number of studs and the length of carbide on the skags the more studs you use the longer the carbide on the skags should be See your dealer s track studding chart Wea...

Page 67: ...Lock Brake Lever Brake System 67 68 113 Throttle Lever 65 Throttle Safety Switch 65 Auxiliary Shut Off Switch Engine Stop Switch 71 83 Ignition Switch 71 83 Taillight Brakelight Headlight 71 Coolant L...

Page 68: ...he manual is your guide to safe and enjoyable snowmobiling experience n Throttle Lever The throttle and brake are the primary controls of your snowmobile Always make sure both are functioning properly...

Page 69: ...lace before operating the snowmo bile n Steering System WARNING Ice and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area fr...

Page 70: ...lic system Refer to the brake bleeding infor mation on page 115 Brake Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 11...

Page 71: ...place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service...

Page 72: ...vehicle Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damag...

Page 73: ...he follow ing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 125 Rear idler adjusting bolt locknuts Tightness Torq...

Page 74: ...gs Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile n Tip Over Inspections In the event of a tip over or rollover check the oil level before operating the snowmob...

Page 75: ...l throttle or high speeds for extended periods during the break in period Use of non recommended oil may cause serious engine damage Always use the recommended oil for your Polaris snowmobile 1 Fill t...

Page 76: ...attempt to start the engine without using the throt tle If two to three attempts are unsuccessful apply 1 8 to 1 4 throttle while cranking the engine Ease off the throttle immediately when the engine...

Page 77: ...ct the negative usually black cable last When removing jumper cables always disconnect the negative usually black cable first WARNING Loose fitting clothing can get caught in the engine when the vehic...

Page 78: ...able to the fuel system or fuel lines 8 Pull back the red plastic boot covering the positive terminal of the weak battery Connect one end of the positive jumper cable to the positive terminal of the w...

Page 79: ...ure that they have a good electrical connections Repeat step 14 16 If the engine still does not start remove the jumper cables as out lined in step 17 and transport the snowmobile to an authorized Pol...

Page 80: ...or sparks in or near the area where refu eling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Neve...

Page 81: ...t Always protect painted surfaces when handling fuel Fuel Level The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1 8th tank There will be approximately one...

Page 82: ...ck or flying debris could cause serious injury or death Stand clear of the front of the machine and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not u...

Page 83: ...use vehi cle speed and engine speed to be limited WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident If the throttl...

Page 84: ...g it several times The lever and cable must return to the idle position quickly and completely 4 If the throttle lever operates properly turn the ignition switch on and go through normal starting proc...

Page 85: ...d Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle Look behind the snowmobile before and while backing Avoid sharp turns Apply throttle slowly Engaging Rev...

Page 86: ...methods for stopping the snowmobile in the event of an emergency See page 80 for more information about the engine stop switch Daily Storage At the end of each ride park the snowmobile on a level sur...

Page 87: ...used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person ridi...

Page 88: ...is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If...

Page 89: ...s become the responsibility of the regis tered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost...

Page 90: ...ver feel O Coolant 107 Inspect level add as needed O Brake fluid 114 O CHANGE EVERY 2 YEARS Hood Latches 66 Secure properly replace if damaged O Seat Latches 65 O Rail Slide 126 Inspect for wear or da...

Page 91: ...Verify alignment adjust as needed O O O Drive Chain 112 Verify tension adjust as needed EVERY Gearcase Oil 100 Check at 500 mi 800 km change every 1000 mi 1600 km O EVERY 1000 1600 Rear Suspension 99...

Page 92: ...es Inspect for wear damage and proper routing replace as needed O O Brake Pads Disc 113 Inspect replace if worn or damaged O O Fuel Vent Lines 104 Inspect replace if worn or damaged O O Ski Toe 128 Ve...

Page 93: ...s recommendations for ambient tempera ture operation NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil bran...

Page 94: ...erature is within the specified range for performing the oil check Allow the engine to cool if necessary When the coolant is within the specified range restart the engine and allow it to idle for no m...

Page 95: ...bottom of the safe operating range on the dipstick 9 If the level is high remove 2 ounces 60 ml and recheck the level NOTICE Do not overfill the oil tank Engine damage may occur Always add oil in sma...

Page 96: ...evel check procedure begin ning on page 90 4 If oil is not present add 1 2 quart 47 l of the recommended oil Reinstall the dipstick start the engine for no more than 5 seconds stop the engine and rech...

Page 97: ...turn over the engine without starting it You may also need an assistant to help with the oil change 1 Position the vehicle on a level surface 2 Make sure the engine coolant temperature is between 145...

Page 98: ...rom the fuse block 11 Reinstall the left side panel 12 Have an assistant use the ignition key to turn over the engine Crank the engine for 15 seconds 13 Wait 30 seconds to allow the starter motor to c...

Page 99: ...einstall the 20A EFI Fuse 21 Remove the dipstick from the oil tank Add 2 quarts 1 9 liters of the recommended oil Reinstall the dipstick 22 Start the engine and allow it to idle for 3 5 minutes Make s...

Page 100: ...ure to avoid overfilling If the filling and checking procedure is not completed within three minutes rein stall the dipstick Restart the engine and allow it to idle for no more than 20 seconds to circ...

Page 101: ...or replace the element as recommended The foam oil breather element is located inside the airbox 1 Open the hood 2 Release the airbox cover retain ing clips and remove the cover 3 Remove the foam brea...

Page 102: ...ricate liberally as shown Front Suspension The front suspension and steering components do not require lubrica tion Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Seaso...

Page 103: ...umbers of Polaris products The dipstick is located on the lower front side of the gearcase Maintain the oil level in the safe operating range between the upper and lower marks on the dipstick 1 Positi...

Page 104: ...breather element See page 98 1 Position the vehicle on a level sur face 2 Remove the drain plug and drain the oil into a drain pan Allow the oil to drain completely Tip The sealing surfaces on the dr...

Page 105: ...he engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile Use recommended spark plugs with the proper gap Use only resistor...

Page 106: ...engine and the service Tip The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjust ments Wet Fouled Spark Plu...

Page 107: ...laris dealer Do not attempt to service the fuel pump Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on pag...

Page 108: ...s or more as shown tighten the belt or install a new belt Air Filter Inspect the air filter for oil and dirt accumulation at the intervals out lined in the Periodic Maintenance Table beginning on page...

Page 109: ...perform this procedure with the engine running 1 Allow the engine and exhaust system to cool completely 2 Open the hood 3 Inspect the muffler and pipes for cracks or damage Check for weak or missing r...

Page 110: ...tem Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part CAUTION Steam and hot liqu...

Page 111: ...your skin Never remove the pressure cap when the engine is warm or hot or if any part of the cooling system is warm or hot NOTICE Operating the snowmobile when the high temperature indicator light is...

Page 112: ...service Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main tenance Table beginning on page 87 In addition bleed the cooling sys tem any time one or mor...

Page 113: ...the filler neck until the coolant level reaches the top of the rear cooling loop return line on the inside of the filler neck The opaque coolant reservoir bottle should be full but may have a small ai...

Page 114: ...re cap and add coolant through the filler neck until the reservoir bottle is full Reinstall the pressure cap and start the engine 12 Repeat steps 10 11 until the coolant level in the bottle no longer...

Page 115: ...chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut 3 Finger tighten the adjuster bolt until it can no longe...

Page 116: ...e vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backin...

Page 117: ...t glass in the brake reservoir If the fluid is suffi cient the sight glass will be black If the sight glass is any color other than black add brake fluid Keep the master cylinder cover free of dirt an...

Page 118: ...2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 6 8 cm below the lip of the reservoir open ing Reinstall the gasket and cover 3 Slip a rubber tube over the ball of th...

Page 119: ...b withdraw the bulb from the housing 5 Grasp the bulb by its metal base and carefully separate the bulb from the harness Installing Halogen Bulbs 1 Hold the bulb by its metal base and install it into...

Page 120: ...EFI RELAY EX SENSOR GAUGE 20A REVERSE SHIFT Exhaust sensor Gauge Reverse shift Accessory projector beam relay Diagnostic plug IGNITION 20A Ignition relay power EFI 20A Cam phase sensor ECU hold on po...

Page 121: ...st be performed by an authorized Polaris dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty The bushings in the weights and rollers of Polaris...

Page 122: ...om temperature Reinstall it before starting the snowmobile n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge on the be...

Page 123: ...o ensure forward engagement before attempting to remove the belt Tip For easier accessibility make sure the clutch tool access hole is visible between the 11 00 and 2 00 positions of the clutch sheave...

Page 124: ...operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt removal procedures 2 Rotate the...

Page 125: ...commended for your model Track Inspection WARNING Broken track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Neve...

Page 126: ...de rail requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in ex...

Page 127: ...se serious damage to the snowmobile which can result in loss of vehicle control and serious injury or death Always maintain the track tension as specified 1 Turn the engine off 2 Lift the rear of the...

Page 128: ...to provide equal adjustment on both sides of the track 9 Repeat the measurement on the other side of the track Tip Check more frequently when the snowmobile is new 10 Start the engine and slowly rotat...

Page 129: ...re evenly spaced on each side If the track runs to the left loosen left locknut and tighten the left adjusting bolt If the track runs to the right loosen right locknut and tighten the right adjusting...

Page 130: ...127 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners...

Page 131: ...th the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement betw...

Page 132: ...h Replace skags as recommended Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter Carbide skag...

Page 133: ...y cable last 5 Lift the battery out of the vehicle Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully...

Page 134: ...ed during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the...

Page 135: ...xplode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Always verify battery...

Page 136: ...paint The snowmobile should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile compon...

Page 137: ...ured away from sharp edges steering linkage moving parts and hot exhaust parts Track and Suspension Moderate track tension should be maintained dur ing summer storage The snowmobile should be supporte...

Page 138: ...etic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz car...

Page 139: ...ay be iced up or fro zen to the ground Jammed or broken chaincase sprocket or chain See your dealer Mechanical failure See your dealer Probable Cause Solution Low battery voltage Recharge the battery...

Page 140: ...Clogged fuel filter Replace the filter Low battery voltage Recharge the battery to 12 8 VDC Poor engine compression See your dealer Mechanical failure See your dealer Probable Cause Solution Weak spar...

Page 141: ...rk plug Inspect clean and or replace spark plug Kinked or plugged fuel vent line Inspect and replace Clogged air filter Inspect and clean or replace Air flow through intake is too warm Boost is limite...

Page 142: ...tor Stop and cool the engine Clean snow and debris from the radiator Probable Cause Solution Worn drive belt Replace with the recommended belt Excessive belt sheave clearance See your dealer Probable...

Page 143: ...ng Set static sag see page 54 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Adjust limiter straps see page 55 Machine darts from side to side Check ski alignm...

Page 144: ...Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine perfor mance Check for fouled plugs or...

Page 145: ...contained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the followi...

Page 146: ...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 147: ...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 148: ...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 149: ...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 150: ...overage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are requi...

Page 151: ...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 152: ...omponents of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited...

Page 153: ...ue to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing compet...

Page 154: ...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 155: ...152 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

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

Page 157: ...Bleeding 109 111 Cooling System Flushing 109 D Digital Display 37 Disabled Operators 13 Drive Belt 19 Drive Belt Adjustment 119 Drive Belt Condition 119 Drive Belt Deflection 119 Drive Belt Installat...

Page 158: ...eplacement 48 49 MFD Components 37 MFD Digital Display Programs 40 47 MFD Settings 38 39 N Noise 6 O Oil Engine 90 97 Gearcase 100 101 Oil Breather Element 98 Oil Breather Filter 105 Oil Change 94 97...

Page 159: ...nsion Lubrication Rear 99 Suspension Performance Tips 53 Suspension Front 50 Switch Stop 80 Switch Throttle Safety 80 T Throttle Cable Lubrication 99 Throttle Lever 65 81 Throttle Safety Switch 65 80...

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