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Polaris Widetrak LX, Owner'S Manual

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Polaris Widetrak LX Owner'S Manual Download Page 88

85

MAINTENANCE

Clutch System

Drive Belt Installation

1. Drop the drive belt over the 

drive clutch and pull back 

the slack.

NOTE:

To ensure satisfactory 

belt life, install belts so 

they operate in the 

same direction of rota-

tion by positioning the 

identification numbers 

so that you can read 

them. If required, sepa-

rate the sheaves as 

outlined 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 the bot-

tom portion over the outer 

clutch sheave. Work the belt 

to the outer edge of the 

sheave.

4. Close the clutch guard and 

reinstall the retaining pin.

5. Close and secure the hood 

and release the parking 

brake.

Summary of Contents for Widetrak LX

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Page 3: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 4: ...r safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is i...

Page 5: ... and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part i...

Page 6: ...tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 38 This section explains procedures that must be performed before riding Operation 46 This section explains proper engine break in operation of features and general operating procedures Maintenance 59 This section defines your role and your dealer s role in your snowmo bile s regular maintenance Polaris ...

Page 7: ...oll them in driver s training and safety courses sponsored by local or state organizations Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed...

Page 8: ...that snowmobiles conform to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter ...

Page 9: ...th one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number ___________________________________________________ Tunnel VIN ____________________________________________________________ lower right side of the tunnel Engine Serial Number ___________________________________________________ right front side of engine crankcase Key Number ____________...

Page 10: ...heir meanings before reading the manual The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage...

Page 11: ...veling at high speeds Extra caution must be observed to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times We strongly recommend that the operator check major and vital safety compo nents before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result f...

Page 12: ...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 snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and align ment pr...

Page 13: ...adio or cel lular telephone For added protection carry the following items on your snowmobile at all times Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience but under many conditions the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle brake and ...

Page 14: ...2 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet fac...

Page 15: ...ving 1 Up Some Polaris snowmobiles are designed for a single rider only A decal on the console of these models indicates single rider operation Driving 2 Up Some 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 location Machines designed for two riders shoul...

Page 16: ...r second If you look back for only two seconds 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 headlight and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your machine to a stop in the distance illumi nated by the headlight W...

Page 17: ...r view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness Always check with local residents or authorities for general information on conditions when traveling on lakes and streams that are strange to you Before riding your machine on a frozen body of water be sure the ice is thick enough to support the machine and its operator as well ...

Page 18: ...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 conditions above you as you travel in moun tainous terrain Before riding in mountainous terrain call or log on to your local ava lanche advisory to get current weather and snow stability information Fo...

Page 19: ...ow or ice may lead to loss of vehicle control and result in seri ous injury or death Slow down to maintain control under these condi tions It s dangerous to drive on ice or other slippery surfaces If it s unavoid able use extreme caution and operate at speeds no faster than a walk Never attempt an abrupt change of direction The chance of spin out increases under these conditions WARNING Ice and sn...

Page 20: ...her side of the hill If you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop the 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 downhi...

Page 21: ... remote don t defeat the purpose of the guard by removing it It s pro vided for your safety Drive Belt Do not operate the engine with the drive belt removed Any servicing that requires operation without a belt must be performed by your dealer Operation of the engine with the belt removed may result in personal injury or damage to the engine WARNING When driving on long downhill stretches pump the ...

Page 22: ...s preci sion balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the machine into motion but always operate within safety limits See Starting the Engine on pag...

Page 23: ... down the snow in front of the machine so that when the throttle is opened the snowmobile will be able to climb up and over the snow NOTICE When operating on icy surfaces or hard packed snow avoid overheating the slide rail and track Lack of lubrication and cooling will cause overheating of the slide rail and track resulting in premature wear and failure If frequently operating in low cooling cond...

Page 24: ...l as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide pro tection under normal riding conditions Your snowm...

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 Wind Speed in KPH Actual Thermometer Reading _C 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 Equivalent Temperature _C Calm 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 3 0 4 7 11 14 18 22...

Page 26: ... 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 running Do not operate engine with this guard open Never run engine with drive belt removed Never service clutches yourself see your dealer Air Box Warning This warning decal is found under the hood on applic...

Page 27: ...h Reverse Warning Polaris Widetrak snowmobile is equipped with standard reverse The reverse warning decal is located above the instrument hous ing WARNING Reverse operation even at low speeds can cause loss of con trol resulting in serious injury or death To avoid loss of con trol always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply thro...

Page 28: ...s wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control the vehicle When operating on hard packed snow ice or when crossi...

Page 29: ... fuel gauge 2 Ignition Switch 3 Brake Lever 4 Speedometer may include indicator warning lights 5 Reverse Indicator 6 Mountain Bar 7 Engine Stop Switch see page 54 8 Throttle Control 9 Choke 10 Recoil Starter Handle 5 4 3 2 1 10 9 7 8 6 GeneralRepresentation ...

Page 30: ...cessories are available from your Polaris dealer 1 Headlight Dimmer Switch 2 Parking Brake Lock 3 Handlebar Grip Warmer Switch 4 Thumbwarmer Switch 5 Electronic Reverse Button Fuel Valve The fuel valve is located under the hood Turn the fuel valve off when ever the snowmobile is stored or parked 1 Turn the valve clockwise to turn off the fuel supply 2 Turn the valve counter clock wise to turn on t...

Page 31: ...lap 10 Track 11 Suspension 12 Trailing Arm 13 Nosepan 14 Front Bumper do not use for pulling or dragging the snowmobile 15 Skis Cargo Rack Always secure cargo before operating Do not exceed the rack weight limit specified on the cargo rack decal Do not allow a passenger to sit on the seat back or the cargo rack 14 1 2 3 4 5 6 8 9 11 10 12 15 13 7 ...

Page 32: ...ther operator or passenger use 1 Loosen the upper adjustment knobs to raise or lower the backrest 2 Loosen the lower adjustment knobs to move the back rest forward for operator use or rearward for pas senger use 3 Always tighten the knobs Operator Passenger Raise Lower ...

Page 33: ...th factory settings and then customizing each adjustment individually to suit rider preference The machine should be methodically tested under the same conditions after each adjustment trail and snow conditions vehicle speed riding position etc until the best ride is achieved Adjustments should be made to one area at a time in order to properly evaluate the change IFS Components 1 Skis 2 Front sho...

Page 34: ...jounce bumper down as far as it will go on the shock rod and test ride the machine The bumper will move up on the rod in direct relation to the amount of travel If the shock travel is full the bumper will be seated at the top of the shock Shock Components 1 Retainer 2 Shock Rod 3 Jounce Bumper 4 Body 5 Threaded Spring Preload Adjuster Nut WARNING Always verify ski alignment before making adjustmen...

Page 35: ...re Front Springs For models without exter nally adjustable or revalv able shocks the front springs can be changed if spring pre load alone isn t sufficient and further adjustment is desired to control suspen sion stiffness Special tools are required to adjust front springs If you feel that your front suspension needs adjustment see your Polaris dealer for more information Front Shock Washers ...

Page 36: ...n at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride In deep snow a new rail slide will offer improved performance over a worn rail slide It can also improve top speed When riding on ice or hard packed...

Page 37: ...ground 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 equally on both sides until the desired 1 1 2 drop is obtained Compensating adjustments for heavy or light drivers or cargo loads can be made by adjusting the rear spring eye bolt length Adjust spri...

Page 38: ... or right for access to the rear nuts NOTE If necessary pry the blocks apart with a screwdriver 3 Adjust the handlebar to the desired angle Be sure the handlebar brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when the handlebar is turned fully to the left or right 4 Torque the front bolts first then torque the rear bolts Torq...

Page 39: ...re terrain Inspect skags frequently Worn skags may reduce steering and braking control on hard packed snow and ice Replace worn skags to maintain proper balance and vehicle control WARNING Loss of control can result in serious personal injury or death Proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard packed snow or ice See your de...

Page 40: ...Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in Non compliance with government industry requirements Voiding of warranty Personal injury to self or others This applies to but is not limited to the following areas brakes clutches fuel systems and exhaust systems NOTE Exhaust systems are critical safety areas that must use approved Polar...

Page 41: ... Page Drive Belt Condition 83 86 Steering System 42 Recoil Rope 43 Parking Brake Lock Brake Lever Brake System 40 41 77 Auxiliary Shut Off Switch Engine Stop Switch 54 Ignition Switch 44 Taillight Brakelight Headlight 44 Suspension Mounting Bolts 96 Skags Wear Bars 95 Ski Saddle and Spindle Bolts 96 Hood Straps Latches 43 Throttle Lever Safety Switch 39 54 55 Rear Wheel Idler Bolts 91 96 Track Ali...

Page 42: ...ays make sure both are functioning properly Squeeze the throttle lever to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not func tion smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately See page 55 n Throttle Safety ...

Page 43: ...ges 78 79 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Also check for the presence of air in the fluid sys tem See pages 78 79 or see your dealer for service Replace brake fluid at least every two years We recommend the use of Polaris DOT 4 high temperature brake fluid See page 105 for the part numbers of Polaris ...

Page 44: ...ghtly enough the lock will move freely into place Do not force the lock or it may break The brake light will illuminate if the parking brake lever lock is set while the engine is running It will also illuminate when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lo...

Page 45: ...igh speeds for extended periods of time with inadequate lubrication could severely damage track rods break track edges and cause other track damage Examples of inade quate lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure caused by operation on ice or under poor lubrication conditions voids the track warranty WARNING ...

Page 46: ...nd 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 every use of the snowmobile n Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear is found see you...

Page 47: ...eck the headlight high and low beam taillight and brake light Replace burned out lamps before operating n Mirrors if equipped Adjust the mirrors so they can be used to their full advantage n Operating Area Before driving check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the machine n Ignition Switch Make sure the engine stops when the ignition switch i...

Page 48: ...start turn the key to START to crank the engine Release the key to the ON position when the engine starts NOTICE Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Damage may result To avoid engine damage do not operate the electric starter or pull rope starter while the engine is running 6 If not equipped with electric start grasp starter h...

Page 49: ... three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle openings and machine speeds to reduce friction on all close fitting machined parts allowing them to break in slowly without damage Use of any lubricants other than those recommended by Polaris may cause serious eng...

Page 50: ...e Oil for this engine See page 105 for the part numbers of Polaris products Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage Oils may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All Polaris oils are compatible with each other Slide Rail and Track Cooling NO...

Page 51: ...move them from side to side This will loosen frozen snow from the ski bottoms allowing the machine to move forward more easily 6 The engine drive system and track are now properly warmed up and the machine may be driven following normal safety practices WARNING A loose track or flying debris could cause serious personal injury or death Stand clear of the front of the machine and the moving track N...

Page 52: ...ons Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not overfill the tank Do not fill the tank neck Do 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 wat...

Page 53: ... per gallon 8 16 milliliters per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol See page 105 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deic ers or water absorbing additives are not required and should not be used NOTICE Prolonged exp...

Page 54: ...hey may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All Polaris oils are compatible with each other Always maintain the oil level above the tank s low level line This is especially important when the machine is operated in mountainous ter rain Maintaining the proper oil level will prevent system aeration and possible loss of pum...

Page 55: ...le fuel may result in piston burning bearing failure or complete engine failure A rich mixture too much fuel too little air may foul plugs and cause generally poor engine 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 filter in the air intake system Eit...

Page 56: ...or altitude range The main jet installed in production is not correct for all altitudes and or temperatures NOTICE A main jet that s too small will cause a lean operating condition and may cause serious engine damage Jet the carburetors carefully for elevation and temperature according to the jetting charts Refer to your Owner s Manual Supplement It s the owner s responsibility to ensure that the ...

Page 57: ...on Test the throttle safety switch system daily before operation 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 slight amount of throttle A properly functioning switch must shut down the engine WARNING Operating the snowmobile with a faulty throttle safety...

Page 58: ... in 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 it s necessary to start the engine the throttle safety switch and engine stop switch may be disconnected from the wire harness When these switches are disconnected the ignition key switch must be ...

Page 59: ...ackshaft All Choke Floods engine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Throttle Safety Switch Interrupts ignition circuit All WARNING Excessive or repetitive use of brakes for high speed stops will cause an over heated brake system This overheated condition could cause sudden loss of brakes and or fire resulting in serious injury or death When traveling on long d...

Page 60: ... shift again The transmission may not always be in the gear indicated by the shift lever Apply the throttle slowly until you re sure which gear is engaged Sometimes the drive belt will drag in the drive clutch causing slight tension in the transmission and making it hard to shift Shutting the engine off will remove this tension and ease shifting This should only happen during the break in of a new...

Page 61: ...ssary NOTICE Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 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 or death DO NOT tow toboggans sleds saucers...

Page 62: ...gine recoil cover The ECI label 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 Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If your snowmobile is equipped with ...

Page 63: ...nowmobile Engine Emissions Limited Warranty and read the maintenance section of your owner s manual You are responsi ble for ensuring that the specified maintenance is performed Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary ...

Page 64: ...tervals 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 period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting t...

Page 65: ... Clean R Replace L Lubricate Item See Page Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Offset Alignment without belt 82 I I I Drive Belt Condition 83 I I I I Clutches disassemble 82 C C C Belt Tension I I I I Clutch Sheaves 86 I I I I ENGINE Engine Mounts I I I I Recoil Rope 43 I I I I Engine Mounting Plate I I I Engine Torque Stop 87 I I I I Cyli...

Page 66: ...ke Pads 77 I I I I Brake Disc I I I I Parking Brakes 41 I I I I Brake System 40 77 I Brake fluid 78 R FUEL MANAGEMENT Pilot Air Screws I I I Carburetor synchronize 52 I I I Idle RPM I I I Throttle Lever 39 55 I I I I I Oil Pump Lever synchronize I I I Throttle Cable 68 L L L Choke Cable 68 I L L L Vent Lines I I I I Throttle Position Sensor I I I Choke 68 I I I Fuel Filter 75 R R Fuel Lines 75 I I...

Page 67: ... 44 I I I I I Headlight 44 I I I I I CHASSIS Ski Toe Alignment I I I Suspension Mounting Bolts I I I I I Steering Fasteners I I I I C Rear Suspension Fasteners I I I I I Suspension Shock Oil I I I I Cooling Fins and Shroud I I I I Drive Shaft Bearings 68 L L L I Jackshaft Bearings 68 L L L I Skags Wear Bars 95 I I I I I Ski Saddle Spindle Bolts I I I I I Ski Pivots 66 L L L L I Ski Spindle 66 L L ...

Page 68: ...Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CHASSIS Rear Suspension Pivot Shafts 67 L L L Camber Alignment I I I Radius Rod Bushings I Handlebar Centering I Track Alignment 92 I I I I I Track Tension 90 I I I I I Front Limiter Strap I I I I I Rail Slide Condition 96 I Chaincase Oil N A I I I R I Gearcase Oil 69 I I I R I ...

Page 69: ...e 105 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 to permit better grease entry into the spindle area Lubricate both of the front ski pivots at the fittings as shown Grease the jackshaft and driveshaft clutch side bearings Use an aerosol lubricant o...

Page 70: ...67 MAINTENANCE Lubrication Rear Suspension WideTrak Rear Suspension ...

Page 71: ... outside the bearing seal approximately two pumps Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as shown Choke and Cable Lubricate the choke slide and cables lightly with oil or grease Before turning the engine off operate the choke intermittently to draw mois ture out of the choke plunger area and...

Page 72: ... the 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 Clean the magnetic plug 2 every 500 miles 800 km and whenever checking or changing lubricant NOTICE Mixing brands or using non recommended lubricants could result in excessive wear to chain sprockets an...

Page 73: ...gine under medium or light duty to have spark plug failure NOTICE A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile Refer to your Owner s Manual Supplement A new engine can cause temporary spark plug fouling due to the preser vative added ...

Page 74: ...e and the service NOTE The tip should not be white A white insulator tip indicates over heating caused by use of an improper spark plug or incorrect carburetion adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use ...

Page 75: ...ically to remove any accumulation of snow NOTICE Operating the snowmobile with the intake filters removed may cause carburetor icing The result will be poor fuel economy or carburetor malfunction Always reinstall the intake filters before operating the snowmobile NOTE These illustrations are general representations Your model may differ Intake Foam Filter and Screen Foam Filter Air Intake Box ...

Page 76: ...n a container or shop towels to catch the contaminated gasoline 3 Slide the clamp away from the drain plug and remove the drain plug from the sediment tube 4 Wipe residue from the plug and reinstall it Reposition and tighten the clamps Continue until all the traps have been emptied WARNING When draining the traps fuel spillage will occur Always work in a well venti lated area away from anything th...

Page 77: ... engine damage Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or balanced is important Properly adjusted carburetors can greatly improve engine performance fuel economy engine life and reliability If you notice any of the following conditions the carburetor may n...

Page 78: ...or damaged fuel lines promptly NOTICE Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly Oil Filter The oil filter on your model is assembled into the oil sending unit located in the bottom of the oil tank This component requires no main tenance If service is performed to the oil...

Page 79: ...the muffler and pipes for cracks or damage Check for weak or missing retaining springs or damper support grommets Drive Chain Tension Your WideTrak is equipped with an automatic chain tensioner No main tenance or inspection should be necessary WARNING Hot exhaust system parts can cause serious burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine run...

Page 80: ...dealer Brake Components 1 Brake Caliper 2 Chaincase 3 Brake Disc 4 Backing Plate 5 Brake Pad Material Replace when thick ness is less than 1 16 inch 1 5 mm WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are 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 p...

Page 81: ...e 105 for the part numbers of Polaris products WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rap idly absorbs moisture from the air The moisture causes the boiling tempera ture of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury WARN...

Page 82: ...bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles 7 After bleeding is complete refill the reservoir to the proper level 8 Re...

Page 83: ...adlight 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 aimed two 2 inches 5 1 cm below the mark placed on the wall in step 4 NOTE Rider weight must be included on the seat 5 Turn the adjustment nut located inside the hood just below the headlamp opening Turn the knob in or o...

Page 84: ...e housing 3 With the wire harness attached to the bulb 3 withdraw the 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 into the housing Carefully flip the spring back into the housing placing it around the wire harness 7 Squeeze the spring together ...

Page 85: ... optimum perfor mance Please see your Polaris dealer if you experience a decrease in performance Clutch Center Distance Refer to your Owner s Manual Supplement for recommended center distance for your machine If adjustment is necessary see your dealer WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern see your dealer immediately Do not oper...

Page 86: ...ubleshooting on page 107 Periodically check the condition and tension of the drive belt and always carry a spare Inspect the belt for signs of excessive wear frayed edges missing cogs cracks and excessive looseness Replace the belt if any of these conditions exist NOTE A worn belt will continue to function but will not deliver maxi mum performance Always carry a spare belt in case of an emergency ...

Page 87: ...tion 2 Turn the ignition key off Wait for the engine to stop completely 3 Lock the parking brake if equipped 4 Open the hood 5 Remove the clutch guard retain ing pin and open the clutch guard 6 Firmly grasp the belt midway between the clutches and pull upward and rearward to remove See illustration ...

Page 88: ...t you can read them If required sepa rate the sheaves as outlined 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 the bot tom portion over the outer clutch sheave Work the belt to the outer edge of the sheave 4 Close the clutch guard and reinstall t...

Page 89: ...s measurement should be 1 1 4 inches 32 mm Drive Belt Adjustment Belt deflection should be adjusted without removing the clutch from the jackshaft 1 Loosen the 7 16 inch jam nut on the belt width adjuster 2 Using a 1 8 inch Allen wrench adjust the threaded set screw as needed NOTE Turn the set screw in clockwise to increase the distance between the sheaves and out counterclockwise to decrease the ...

Page 90: ...m the engine case Adjust if necessary and lock the jam nut Tool Kit A tool kit is included with each machine for emergency and routine maintenance Always keep the tool kit with the snowmobile Chain Tension Maintain the proper chain tension as outlined on page 76 Fall Tune Up For maximum performance arrange for a fall service tune up with your Polaris dealer 010 030 in 25 75 mm ...

Page 91: ...3 Carefully examine the track along the entire length of each rod Bend the track to check for break age 4 Replace the track if any rod damage is found WARNING Broken track rods are a serious safety hazard They can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power ...

Page 92: ...ons 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 conditions will void the track warranty WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in seriou...

Page 93: ...nt where the weight is hanging 4 Check for specified slack between the wear surface of the track clip and the plastic rail slide WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine run ning WARNING Improper track tension can cause...

Page 94: ... measure ment on the other side of the track NOTE Check more fre quently when machine is new 9 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 10 Check track alignment see page 92 and adjust as necessary 11 Tighten the locknuts 12 Tighten the idler shaft bolts Torque to 35 ft lbs 47 5 Nm Adjusting Screw Locknut Slack Measureme...

Page 95: ...ast five complete revolutions 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 runs to the left loosen the left locknut and tighten the left adjusting bolt If the track runs to the right loosen the right locknut and tighten the right adjusting bolt 4 ...

Page 96: ...3 MAINTENANCE Steering System Steering Inspection Each week or before a long ride check fasteners and tighten if neces sary Specific fasteners that should be checked are marked with a in the illustration ...

Page 97: ...tween the skis at point X should be 1 8 1 4 inch 3 6 mm greater than at point Y NOTE If the skis are misaligned we recommend that your dealer cor rect the alignment since camber adjustment may also be affected WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski align ment or camber adjustment See your...

Page 98: ...the ground 2 Remove the attaching hardware 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 skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommended skags If you install longer or more aggressive...

Page 99: ...down time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the follow ing items on a weekly basis or before any long trip n Check suspension mounting bolts for tightness n Check rear idler wheel bolts for tightness See page 91 n Check rear idler adjusting bolt locknuts for tightness n Check front torque arm limiter strap condition n Check rail slide co...

Page 100: ...ains 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 OF CHILDREN EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Call physician immedi ately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks open flames cigarett...

Page 101: ...ttery hold down straps 2 Remove the battery vent tube from battery 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable last 5 Carefully lift the battery out of the snowmobile Do not tip it side ways or spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage t...

Page 102: ...obstructions and securely installed Route the vent tube properly to prevent kinks and to allow for proper drainage 4 Coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables and vent tube are properly routed WARNING Battery gases could accumulate in an improperly installe...

Page 103: ...l Store it in a cool dry place Check and or charge monthly Have the battery tested and recharged before reinstalling it in the vehicle If a battery with a low charge freezes the cells could be damaged Always maintain a full charge on a stored battery See the table below Charge condition Will freeze at 100 75_ F 59_ C 75 24_ F 31_ C 50 0_ F 18_ C 25 13_ F 11_ C 0 18_ F 8_ C ...

Page 104: ...ace and support it at the rear with an appropriate track stand The track should be suspended approximately 4 inches 10 cm off the ground Remove the key and cover the machine NOTE Polaris has accessory covers and track stands available to fit all mod els See your dealer for more infor mation ...

Page 105: ...st and corrosion on precision engine parts during storage Whenever the machine is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the can See page 103 Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the can running the engine for five minutes to get ad...

Page 106: ... 5 Pour approximately two ounces of Polaris injector oil into the spark plug hole 6 Wait one to two minutes and perform steps 3 to 5 on remaining cyl inders 7 Replace the spark plugs and lower the machine to the floor Controls and Linkage All bushings spindle shafts tie rod ends and cables should receive a light coat of oil or grease Bearings Grease the drive shaft clutch side bearing with Polaris...

Page 107: ...rp edges steering linkage moving parts and hot exhaust parts Battery Always prepare and maintain the battery as outlined on page 97 Track and Suspension Moderate track tension should be maintained during summer storage The machine should be supported off the ground to allow the track to hang freely Transporting the Snowmobile Whenever the snowmobile is transported 1 Turn the fuel valve off 2 Be su...

Page 108: ...I Synthetic 2 Cycle Engine Oil gal 2874443 VES II Synthetic 2 Cycle Engine Oil 2 5 gal Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyoge...

Page 109: ... Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Front end pushes Check for worn skags Check for binding front suspension shafts and steering com ponents grease all pivot points elevate front of machine Verify sag dimension see page 91 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Increase IFS p...

Page 110: ...e RPM Avoid riding in high ambient temperatures Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine performance Check for carb and choke synchronization fouled plugs debris in the carbs and water ice or dirt in the gas tank or fuel line Loading...

Page 111: ...rance and replace if neces sary SEE YOUR DEALER Harsh drive clutch engage ment Drive belt worn or too narrow Replace drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for applica tion Replace drive belt Clutch alignment out of spec Adjust alignment offset Engine mount broken or loose Inspect and adjust or replace SEE YOUR DEALER Machine fails to move Clutc...

Page 112: ... Worn drive belt Inspect and replace if necessary Excessive belt sheave clearance SEE YOUR DEALER Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Engine doesn t start electric start models Wire connections SEE YOUR DEALER Engine doesn t turn Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inadequate fuel supply broken parts or improper cooling Hydrostatic l...

Page 113: ...ied Poor engine compression Running too lean a mixture too small a main jet will cause seizure resulting in loss of power SEE YOUR DEALER This indicates a major engine problem that must be repaired before engine is run Engine lacks power Fouled or defective spark plug Change and test operation Fuel filter loss of high RPM power Check fuel filter flow Disconnect hose and drain about 1 2 cup Fuel fl...

Page 114: ... contained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following information 1 Serial number 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experienced 6 Length of time and conditions of operation 7 Previous correspondence Use the page pro...

Page 115: ...er reports theft NOTE A In addition to notifying the proper law enforcement officials the owner must call Polaris Customer Service NOTE B Owners must provide their name address telephone num ber and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in n...

Page 116: ...s not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for pur poses other than for which it was manufactured The warranty does not cover any dam ages that occur during t...

Page 117: ...st present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at Polari...

Page 118: ...overage in the event of a warranty claim This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamina...

Page 119: ...Coverage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes Damage due to accident fire explosion theft or other causes beyond Polaris control Damage caused by the failure o...

Page 120: ...take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of t...

Page 121: ...at are covered by this warranty This includes all components whose failure increases the snowmobile engine s emissions Replacing or repairing other components not covered by this warranty is the responsibility of the snowmobile owner The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or pr...

Page 122: ...entified in the owner s manual Polaris can deny an emissions warranty claim if any specified critical emissions related maintenance is not performed Performance of other scheduled maintenance is strongly recommended but is not necessary to keep the emissions related warranty valid Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your sn...

Page 123: ...er each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km ...

Page 124: ...121 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 125: ...122 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 126: ...123 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 127: ...ch Center Distance 82 Clutch Cover Warning 23 Clutch Guard 18 Clutch System 82 87 Clutches 19 Clutching Chart 107 Cold Weather Drive Away 19 D Disabled Operators 12 Drive Belt 18 Adjustment 86 Condition 83 Deflection 86 Installation 85 Removal 84 Drive Chain Tension 76 Driver Awareness 14 Driving Downhill 18 Driving in Hilly Terrain 17 Driving on Slippery Surfaces 16 Driving Responsibly 21 E Elect...

Page 128: ...e Wear 96 Recoil Rope 43 Reverse Operation 57 Reverse Warning 24 Reverse Mechanical 57 Rider Capacity 12 Riding Position 11 S Safety 7 22 Safety Decals 23 25 Shock Components 31 Shock Spring Preload 32 Ski Alignment 94 Ski Skags 95 Slide Rail and Track Cooling 47 Snow Conditions 20 Spark Plugs 70 71 Speed 13 Spring Settings Rear 34 Springs Front 32 Starting the Engine 45 Starting Emergency 57 Stee...

Page 129: ...t 92 Damage 42 Inspection 88 Lubrication 89 Tension 33 90 91 Warm Up 48 Track Cooling 47 Track Seat Warning 24 Transporting the Snowmobile 104 Troubleshooting Belt Wear 107 Troubleshooting Engine 108 110 Troubleshooting Suspension 106 Tune Up 87 V Vehicle Identification Numbers 6 W Windchill Temperature Charts 22 ...

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