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119

MAINTENANCE

General Maintenance

Exhaust System

Check the exhaust system for wear or damage at approximately 2000

miles (3200 km). To inspect, allow the engine and exhaust system to

cool completely. Open the hood and inspect the muffler and pipes for

cracks or damage. Check for weak or missing retaining springs or

damper/support grommets.

Engine Cooling - Liquid Cooled Models

The cooling system on liquid cooled models consists of the following

major components:

Recovery tank

Water pump

Cylinders

Heads

Inlet and outlet manifolds

Pressure cap

Heat exchangers

Hot exhaust system parts can cause serious burns. Allow

adequate time for the exhaust system to cool. Never perform

this procedure with the engine running.

WARNING

Содержание 2002 Snowmobile

Страница 1: ......

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

Страница 3: ...now Our new web site It s designed just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out...

Страница 4: ...2 NOTES...

Страница 5: ...safe and enjoyable operation of your vehicle Your Owner s Manual contains instructions for minor maintenance but major repairs are covered in the Polaris Service Manual and should be performed by a F...

Страница 6: ...eatures Section 4 The Perfect Fit 43 63 This section explains how to tailor the suspension and other features for an optimum riding experience Section 5 Getting Ready to Ride 65 71 This section explai...

Страница 7: ...cle Identification Numbers 9 Section 1 contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in your Owner s Manu...

Страница 8: ...he illustrations and photos used in this manual are general representations Your model may differ n Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical...

Страница 9: ...t 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 manufa...

Страница 10: ...lt to adopt rigorous safety training programs that encourage protection of our environment including wildlife and vegetation Snowmobile clubs and other organizations are working together to protect ou...

Страница 11: ...se Remove the spare key and store it in a safe place Your key can be duplicated only by obtaining a key blank from Polaris and mating it with your existing key The VIN and engine serial numbers are ne...

Страница 12: ...10 NOTES...

Страница 13: ...11 SECTION 2 SAFETY Operator Safety 12 27 Safety Decals and Locations 28 34 Section 2 describes safe vehicle operation and identifies warning decals and their locations...

Страница 14: ...mobile or in this manual alerts you to the potential for personal injury Indicates a potential hazard that could result in serious injury or death Indicates a potential hazard that may result in minor...

Страница 15: ...ngly recommend that the operator check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of cr...

Страница 16: ...of the track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation Serious injuries may result if hands feet or clothing become entangled in the track...

Страница 17: ...proper throttle brake and steering control Use of a backrest may hinder your weight shifting ability This could affect your ability to control this rider active vehicle in certain extreme driving sit...

Страница 18: ...vided on page 26 for your reference To better enjoy your ride be prepared warm and comfortable Control becomes more difficult with two people on board More space is required to make turns and longer d...

Страница 19: ...ning snowmobile operation They ve been established for your protection Always be alert and pay attention to the trail ahead of you Multiplying speed MPH by 1 5 will equal the approximate number of fee...

Страница 20: ...kments may also hide your 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 gen...

Страница 21: ...rd packed snow or ice may lead to loss of vehicle control and result in serious injury or death Slow down to maintain control under these conditions It s dangerous to drive on ice or other slippery su...

Страница 22: ...er side of the hill If you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling bac...

Страница 23: ...emote don t defeat the purpose of the guard by removing it It s provided for your safety Do Not Operate Engine With Drive Belt Removed Any servicing that requires operation without a belt must be perf...

Страница 24: ...Away Whenever your snowmobile has been parked for a length of time especially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttl...

Страница 25: ...track and or engine If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the throttle is opened the snowmobile will b...

Страница 26: ...these models indicates single rider operation See page 30 for decal location Driving 2 Up Some Polaris snowmobiles are designed for two riders A decal on the hood of these models indicates that the v...

Страница 27: ...y course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safety course Everyone can benefit from the course n Don t jump your snowmobile Jumpi...

Страница 28: ...0 60 5 48 37 27 16 6 5 15 26 36 47 57 68 10 40 28 16 4 9 21 33 46 58 70 83 95 15 36 22 9 5 18 36 45 58 72 85 99 11 2 20 32 18 4 10 25 39 53 67 82 96 11 0 12 4 25 30 16 0 15 29 44 59 74 88 10 4 11 8 13...

Страница 29: ...27 33 38 45 50 20 4 9 17 23 29 36 42 48 54 61 30 7 13 21 28 35 42 48 55 63 69 40 9 16 24 32 39 47 53 61 69 76 50 11 18 26 34 41 49 57 64 73 80 60 12 19 27 35 43 51 59 66 75 82 70 13 20 28 36 44 52 60...

Страница 30: ...djustment 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 Airbox Warning Decal 2 This warning de...

Страница 31: ...with the track or a fall from seat back may result in severe injury or death Cargo Carrier Warning Decal 5 Machines with a cargo carrier will have this warning decal on the rear rack or on the tailli...

Страница 32: ...on either the console or the hood of your machine indicates whether it s designed for the operator only 1 Up or the operator and a passenger 2 Up For more information on operating capacities see page...

Страница 33: ...s be in the gear indicated by the shift lever Always apply throttle slowly On machines with reverse it is especially important to maintain track tension as specified in the Owner s Manual If specified...

Страница 34: ...or death To avoid loss of control always S Look behind before and while backing S Avoid sharp turns S Shift to or from reverse only when stopped S Apply throttle slowly S For more information see your...

Страница 35: ...added weight and change in weight distribution Reduce vehicle speeds and al low added space for maneuvering since steering control may be reduced S Always wear an approved helmet eye protection and ad...

Страница 36: ...VER LOCK May relax when used for long periods Do not leave brake engaged for more than five minutes ALWAYS Be seated and in position to control vehicle Stop engine before attempting adjustments Know t...

Страница 37: ...35 SECTION 3 FEATURES AND CONTROLS Location of Controls 36 38 Features 39 41 Section 3 illustrates the locations of your snowmobile s controls and features...

Страница 38: ...l machines 1 Fuel Filler Cap some models have a fuel gauge in the cap 2 Ignition Switch 3 Brake Lever 4 Speedometer may include indicator warning lights 5 Tachometer may include indicator warning ligh...

Страница 39: ...Not all models come with these features Refer to your Owner s Manual Supplement for a list of features on your machine Accessories are available from your Polaris dealer 1 Headlight Dimmer Switch 2 Po...

Страница 40: ...ese features are illustrated on this page Not all models come with these features Refer to your Owner s Manual Supplement for a list of features on your machine Accessories are available from your Pol...

Страница 41: ...14 Trailing Arm 4 Handlebar 15 Skis 5 Seat 16 Front Bumper 6 Storage Rear 17 Console 7 Taillights 18 Rear Bumper 8 Backrest 19 Passenger Hand Hold 9 Tunnel Extension 20 Lifting Hand Hold 10 Passenger...

Страница 42: ...Arm 4 Handlebar 15 Skis 5 Seat 16 Front Bumper 6 Storage Rear 17 Console 7 Taillights 18 Rear Bumper 8 Backrest 19 Passenger Hand Hold 9 Tunnel Extension 20 Lifting Hand Hold 10 Passenger Hand Hold S...

Страница 43: ...shield 14 Trailing Arm 4 Handlebar 15 Skis 5 Seat 16 Front Bumper 6 Storage Rear 17 Console 7 Taillights 18 Rear Bumper 8 Backrest 19 Passenger Hand Hold 9 Tunnel Extension 20 Lifting Hand Hold 10 Pas...

Страница 44: ...42 NOTES...

Страница 45: ...tments 49 58 Handlebar Adjustment 59 Backrest Adjustment 59 Accessories 60 63 Polaris offers a wide range of adjustments so that every machine may be set up to suit individual needs This section expla...

Страница 46: ...ould be made to one area at a time in order to properly evaluate the change All snowmobile suspensions have a front and a rear suspension each of which has adjustment options Independent Front Suspens...

Страница 47: ...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 b...

Страница 48: ...ight Turn it to the left to decrease preload In the illustrations at right B indicates high preload and C indicates low preload Increasing the spring preload too much may adversely affect the handling...

Страница 49: ...Shock Valving If you find that spring preload adjustment alone is not sufficient changing the valving of your Foxt or RYDE FXt shocks may give you the ride adjustment you want The purpose of shock va...

Страница 50: ...n of the shock increases stiffening the ride By turning counterclockwise the compression decreases softening the ride The factory setting is in the softest position screw all the way out counterclockw...

Страница 51: ...s point Make adjustments to one area at a time so you can evaluate the change For further assistance see your dealer Suspension Performance Tips DRider weight usually determines the position at which...

Страница 52: ...distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y from X Sag X...

Страница 53: ...vided only as a guideline to be used for initial suspension set up Your set up may vary based on your desired riding style 1 Turn screw clockwise to stiffen compression 2a Limiter strap in high positi...

Страница 54: ...measure the distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y...

Страница 55: ...ailable if greater tension is desired Contact your dealer for more information Rear Torque Arm Adjustment SKS Models On SKS models only the rear torque arm may be lowered from the stock mounting posit...

Страница 56: ...nts to the compression valving by turning the screw located near the base of the shock Adjustment Locate the adjustment screw A near the base of the shock In half turn increments turn the screw clockw...

Страница 57: ...nt screw A near the base of the shock In half turn increments turn the screw clockwise to increase compression valving and stiffen the ride or counterclockwise to reduce compression and soften the rid...

Страница 58: ...vent of suspension coupling these torque arms could move independently of each other Rear suspension coupling links the movement of the front and rear torque arms to each other There are two types of...

Страница 59: ...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 adjustment dot i...

Страница 60: ...tool 1 located in your tool kit To increase weight transfer or ski lift during acceleration move the RRSS to the rearward hole on high position The RRSS may also be rotated to a lower position for eve...

Страница 61: ...andlebar adjuster block bolts to 11 13 ft lbs 1 5 1 8 kg m 5 Replace handlebar cover Backrest Adjustment The passenger backrest on some models is adjustable To move the backrest forward or backward li...

Страница 62: ...all models Order PN 2870668 Use only Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in DNon compliance with government industry requirement...

Страница 63: ...per or excessive stud installation or the use of non Polaris traction products If traction products are added to the track wear strips must be installed in the tunnel to avoid excessive wear Never add...

Страница 64: ...y to add track studs to maintain proper vehicle control Proper balance must be maintained between the number of studs and the length of carbide on skags The more studs used the longer the carbide on t...

Страница 65: ...termine if your model has wear strips Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction accessories Components as viewed from the rear of th...

Страница 66: ...64 NOTES...

Страница 67: ...rottle Freeplay DBrake DFluid Levels DSteering DMirrors DGear Start the Engine and Check 71 DLights DStop Switch DSkis and Track cold warm DPre ride warm up Certain items must be checked before each r...

Страница 68: ...es evenly and smoothly The lever should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly DO NOT start the engine Have the throttle servi...

Страница 69: ...ulic system multiplies the force of your hand squeezing the brake lever Proper operation depends on an adequate supply of air and moisture free hydraulic brake fluid in the system If the brake lever f...

Страница 70: ...vel Firmly depress the brake lever Measure the distance A between the lever and brake block The distance should be no more than 3 4 1 9 cm If the distance is greater than this recommendation the brake...

Страница 71: ...break To release the lock squeeze the brake handle until the lever returns to the unlock position The park brake light on the console will light up when the park brake lever lock is set and the engin...

Страница 72: ...k track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure cause...

Страница 73: ...headlight high and low beam taillight and brake light for normal operation n Mirror Adjustment Adjust your mirrors so they can be used to their full advantage n Check Surroundings to Verify Clear Ope...

Страница 74: ...72 NOTES...

Страница 75: ...78 79 Fuel 80 82 Oil 83 84 Carburetion 85 Engine Stop Switch 86 Throttle Safety Switch 86 Throttle Lever 87 Emergency Stopping and Starting 88 89 Reverse Operation 90 92 Daily Storage 92 Towing 93 Sec...

Страница 76: ...or wants to stop use intermittent choking to the HALF ON position Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start your snowmobile without...

Страница 77: ...utral and the brake engaged This will allow the engine to warm without engaging the drive system NOTE Don t leave the machine in this position for more than five minutes Engine RPM should be at idle b...

Страница 78: ...old flow characteristics Do not operate at prolonged full throttle for the first three hours of operation Vary the throttle openings and machine speeds to reduce friction on all close fitting machined...

Страница 79: ...olaris products We are continuously testing lubricants and provide the highest performance products available for your engine Please refer to the table below to determine the preferred and acceptable...

Страница 80: ...e several revolutions 3 Release the throttle apply the brakes shut off the engine and lower the machine to the ground 4 Grasp the skis by their front loops and move them from side to side This will lo...

Страница 81: ...may be driven following normal safety practices Always inspect for track damage before operating the snowmobile Use of traction products such as studs ice growsers etc will increase the possibility of...

Страница 82: ...ll the tank neck If you get gasoline in your eyes or if you swallow gasoline see your doctor immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and...

Страница 83: ...Fuel Switch Some Polaris snowmobiles are equipped with a key function to adjust the timing on the machine as you change fuels It s very important to the life of your engine that you use this feature W...

Страница 84: ...e are approximately two gallons of fuel left in the tank when the fuel gauge reads RES Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl based fuel sys...

Страница 85: ...visible in the oil tank If oil is not visible continued operation may cause serious engine damage Never mix brands of two cycle oil Serious chemical reactions may occur causing injection system blocka...

Страница 86: ...he illustration indicates a low oil level When the oil reaches the low level mark add one U S quart of oil to the tank Always use a Polaris oil cap never substitute Your Polaris oil cap may be vented...

Страница 87: ...ed by snow build up on the pre filter in the air intake system Either condition may be caused by improper carburetor adjustment All carburetors have been preset at the factory for adequate fuel supply...

Страница 88: ...tionary by exerting pressure on the pivot pin in the direction shown in the illustration B Apply a slight amount of throttle A properly functioning switch must shut down the engine The throttle safety...

Страница 89: ...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...

Страница 90: ...oke Floods engine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Throttle Safety Switch Interrupts ignition circuit All Tether Switch Option Interrupts ignition circuit All E...

Страница 91: ...en the clutch guard 2 Push on the inner sheave of the clutch and rotate clockwise slightly to relieve belt tension 3 Starting at one of the tower struts wind the strap counterclockwise around the clut...

Страница 92: ...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 th...

Страница 93: ...3 Slowly apply the throttle until movement starts and until you are certain you are in reverse NOTE The maximum engine RPM will be 6000 when in reverse NOTE If the engine has stopped running the snow...

Страница 94: ...the success of this reverse system To set for higher altitude start the engine and hold the button down until the light on the instrument panel flashes rapidly then release the button This is the set...

Страница 95: ...ith a rope No braking power can be applied to an object being towed with a rope Only a stiff metal pole connecting the towed object and tow hitch on the snowmobile should be used If passengers are to...

Страница 96: ...94 NOTES...

Страница 97: ...11 139 Track Maintenance 140 143 Steering System 144 147 Suspension Maintenance 148 149 Extended Storage 150 152 Battery 153 155 This section defines your role and your dealer s role in your snowmobil...

Страница 98: ...continue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registe...

Страница 99: ...r operation Daily 66 86 Check operation of headlights taillight brakelight Daily 71 129 Check park brake function Daily 69 Secure hood Daily 70 Check track alignment X 142 Steering arm and tie rod end...

Страница 100: ...pivot X X X 101 Grease driveshaft bearing always perform before storage X X 107 Check and drain water trap X X 116 Grease rear suspension pivot shafts X X 107 Grease jackshaft bearing always perform b...

Страница 101: ...tenance and services performed on the snowmobile 150 Mile 240 km Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 1000 Mile 1600 km Maintenance Insp...

Страница 102: ...Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Type of Service Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technici...

Страница 103: ...spindles Raise the front end of the machine to permit better grease entry into the spindle area DLubricate both front ski pivots at fitting as shown DGrease jackshaft and driveshaft clutch side beari...

Страница 104: ...ation affects your ride and the life of your suspension For detailed information about suspension lubrication and adjustments see your Polaris dealer NOTE The following illustrations are general repre...

Страница 105: ...103 MAINTENANCE Lubrication L L L L L L L L L...

Страница 106: ...104 MAINTENANCE Lubrication L L L L L L Both sides L L L L...

Страница 107: ...105 MAINTENANCE Lubrication L L L L L L L L L L L L...

Страница 108: ...106 MAINTENANCE Lubrication Suspension Lubrication X 10 EDGE L L L L L...

Страница 109: ...ing seal may take only two pumps Push the clutch back onto the shaft and replace the clutch retaining bolt Torque to 18 ft lbs 2 48 kg m Driveshaft Bearing Greasing Inject grease into the fitting on t...

Страница 110: ...f turn the handlebars to the left and lubricate liberally as shown Choke and Cable Lubrication Lubricate the choke slide 2 and cables with Polaris Cable Lubricant PN 2870510 Before turning the engine...

Страница 111: ...oil level place the machine on a level surface The oil level should be between the safe marks on the dipstick A Add Polaris chaincase oil PN 2871280 through the dipstick opening Do not overfill Flush...

Страница 112: ...surface The oil level should be between the safe marks on the dipstick A See your Polaris dealer for the recommended oil for your machine Do not overfill NOTE Clean the magnetic plug B every 500 mile...

Страница 113: ...top of the foam filter periodically to remove any accumulation of snow NOTE These illustrations are general representations Your model may differ 1 Intake Foam Filter 2 Air Intake box 3 Dash Cowl Ope...

Страница 114: ...ill cause excessive fouling and engine malfunctioning In selecting a spark plug heat range for production a manufacturer assumes that the engine will be operated under extreme heavy duty conditions an...

Страница 115: ...often cause a spark plug to appear too dark or too light in color Before changing spark plug heat ranges be sure the correct main jet is installed in the carburetor s Refer to the Owner s Manual Supp...

Страница 116: ...g rotating clockwise 4 Torque to 18 22 ft lbs 2 5 3 kg m 5 Check spark plug gap refer to your Owner s Manual Supplement 6 Install spark plug cap If spark plug color indicates overheating the cause of...

Страница 117: ...nance follow the oil recommendation chart on page 77 The use of other lubricants may cause improper function of the valve mech anism and increase the frequency of required cleaning due to excessive bu...

Страница 118: ...off 2 Position a container or shop towels to catch the contaminated gasoline 3 Slide the clamp 1 away from the drain plug 2 and remove the drain plug from the sediment tube 4 Wipe residue from the pl...

Страница 119: ...of all trapped air See your dealer for instructions or have your dealer perform the filter change and bleeding operation for you NOTE The direction of the arrows indicates the direction of flow throug...

Страница 120: ...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 follow...

Страница 121: ...age Check for weak or missing retaining springs or damper support grommets Engine Cooling Liquid Cooled Models The cooling system on liquid cooled models consists of the following major components DRe...

Страница 122: ...mperature indicator light is controlled by a switch in the engine cooling system If the engine coolant reaches a certain temperature the switch completes a circuit that turns the light on If you must...

Страница 123: ...roperly Recovery System Models If the coolant level becomes low in the recovery tank bleed the system of any trapped air Visually inspect the coolant filter B and replace it if it s dirty 1 Fill the r...

Страница 124: ...icated mark 5 Start the engine and run at a fast idle for two to three minutes Occasionally loosen the bleed screw to purge any trapped air in the system 6 Shut offtheengine and check therecovery tank...

Страница 125: ...coolant extrusions will be warm 5 If needed fill coolant to maximum recommended mark 6 Replace the pressure cap and carefully lower the front end of the machine Drive Chain Tension To obtain correct c...

Страница 126: ...ss than 1 2 1 3 cm Brake pads must be replaced when the brake pad material becomes thinner than the backing plate approximately 1 16 A kit is available for replacing brake pads See your dealer A Prope...

Страница 127: ...Plate 5 Brake Pad Material Replace when thickness is less than 1 16 Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops as described on page 124 th...

Страница 128: ...the sight glass is any color other than black add brake fluid Use only Polaris DOT 3 high temperature brake fluid PN 2870990 Polaris brake fluid is sold in 12 oz bottles After opening a bottle of bra...

Страница 129: ...e Then unscrewbleeder valve3 4 ofa turn to release air 5 Close bleeder valve and release brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbl...

Страница 130: ...and measure the clearance between the lever and the brake block This distance brake lever reserve A should be no more than 3 4 1 9 cm If brake lever reserve exceeds this amount see your dealer for ser...

Страница 131: ...he center of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be a...

Страница 132: ...y metal base and carefully separate bulb from harness Installing the Bulb 1 Hold bulb by metal base and install into wire harness 2 Insert bulb into housing 3 Carefully flip spring back into housing p...

Страница 133: ...hdraw from housing Installing the Side Bulbs 1 Hold bulb assembly by plastic base and plug into wire terminal 2 Insert bulb assembly into housing 3 Turn bulb assembly 1 4 turn to left to secure in hou...

Страница 134: ...equipped 3 Grasp the belt firmly midway between the clutches and pull upward and rearward Remove the belt Electronic Reverse Belt Removal 1 Remove ONE of the three belt tension adjuster bolts A and s...

Страница 135: ...portion over the outer clutch sheave B Work the belt to the outer edge of the sheave Release parking brake if it s locked 4 Close the clutch guard and reinstall the retaining knob or pin Electronic Re...

Страница 136: ...such as adding or removing weights will void the warranty If you become aware of higher than normal clutch engagement an unusual vibration or an unusual shift pattern contact your dealer immediately...

Страница 137: ...or this reason Polaris recommends that only O E M belts be used Other belts may match the dimensions but can drastically change the shift pattern resulting in poor performance See your dealer for serv...

Страница 138: ...learance should be a minimum of 010 to a maximum of 030 from the engine case 2 Adjust if necessary and lock the jam nut Reverse Kit Maintenance If your snowmobile is equipped with reverse or if you ha...

Страница 139: ...r snowmobile some maintenance will be required Follow these recommendations Chain Tension Maintain the proper chain tension as outlined on page 123 Oil Level Maintain the oil level between the safe ma...

Страница 140: ...le E Wrench F Shielded screwdriver only models with Indy Select or AFX shocks Always keep the tool kit with the snowmobile If necessary a replacement tool kit may be purchased from your Polaris dealer...

Страница 141: ...inter Survival Kit S Trail Map S Owner s Manual S First Aid Kit Fall Tune Up For maximum performance arrange for a fall service tune up with your Polaris dealer His experienced and trained service tec...

Страница 142: ...3 cm WideTrak Type 10 lbs 4 54 kg 16 ahead of rear idler shaft 3 4 1 1 9 2 5 cm XTRA Lite 121 133 136 10 lbs 4 54 kg 16 ahead of rear idler shaft 3 8 1 2 1 1 3 cm Edge RMK 136 10 lbs 4 54 kg 16 ahead...

Страница 143: ...rear idler wheel NOTE Measure at the point where the weight is hanging 4 Check for specified slack between the wear surface of the track clip and the plastic Hi fax C If the track needs adjustment 5...

Страница 144: ...Misalignment will cause excessive wear to the track and slide rail 1 Safely support the rear of the machine with the track off the ground 2 Start the engine and apply a small amount of throttle until...

Страница 145: ...esulting in excessive wear NOTE If excessive Hi fax wear occurs due to poor snow conditions additional wheel kits are available See your dealer for more information IMPORTANT Track damage or failure c...

Страница 146: ...djustment Each week or before a long ride check fasteners and tighten if necessary Specific fasteners that should be checked are marked with a in the following illustrations CRC Suspension With Rack S...

Страница 147: ...n the skis at point X should be 1 8 to 1 4 greater than at point Y NOTE If the skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may also be affected Impr...

Страница 148: ...146 MAINTENANCE Steering System X Y 10 10 All other steering systems Edge IFS Steering System X Y 10 10...

Страница 149: ...ineso the skis are approximately 6 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the forward portion of the skag Reverse this procedure for new skag installati...

Страница 150: ...aler for Hi fax replacement NOTE Hi fax wear pat terns are somewhat different on XTRA 12 suspensions The rear portion will wear rapidly at first After this initial break in period the rapid wear will...

Страница 151: ...nowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components Cleaning and Preservation of Hood Chassis and Trim Proper storage starts with clea...

Страница 152: ...is PN 2870791 Follow the engine fogging instructions provided on the can Always add a fuel conditioner stabilizer or Premium Carbon Clean PN 2871326 to the fuel tank Follow the instructions on the can...

Страница 153: ...at bottom dead center BDC the lowest position in the cylinder On twin cylinder models the opposite piston will be up 5 Pour approximately two ounces of Polaris injector oil into the spark plug hole 6...

Страница 154: ...le Whenever the snowmobile is transported 1 Turn the fuel valve clockwise to OFF to shut off the fuel supply 1 Turn the valve counter clockwise to ON to turn the fuel supply on 2 NOTE The fuel valve i...

Страница 155: ...or clothing If contact occurs seek immediate medical attention KEEP OUT OF REACH OF CHILDREN EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia be...

Страница 156: ...sconnect red positive battery cable second 5 Carefully lift the battery out of the snowmobile Do not tip it sideways or spill electrolyte Tap water contains minerals that will damage a battery and sho...

Страница 157: ...l the battery vent line It must be free from obstructions and securely installed Routethevent lineproperlyto preventkinks andto allow for proper drainage 3 Connect and tighten the red positive cable f...

Страница 158: ...156 NOTES...

Страница 159: ...157 SECTION 8 TROUBLESHOOTING Suspension Troubleshooting 158 162 Belt Troubleshooting 163 Engine Troubleshooting 164 166 Section 8 is a quick reference guide to solving problems...

Страница 160: ...unter clockwise Adjust front track shock spring to less preload Machine darts from side to side Make sure skis are aligned properly Make sure spindles and all steering components are free turning Make...

Страница 161: ...ping by turning screw counter clockwise Machine darts from side to side Make sure skis are aligned properly Make sure spindles and all steering components are free turning Ensure use of E Z Steer skag...

Страница 162: ...oper track tension Machine darts from side to side Make sure skis are aligned properly Make sure spindles and all steering components are free turning Make sure skags are straight on skis Check Hi fax...

Страница 163: ...miter strap on front torque arm to high position See your dealer for optional mounting Too little weight transfer when climbing Verify sag measurement refer to set up decal or page 50 Adjust torsion s...

Страница 164: ...les and all steering components are free turning Make sure skags are straight on skis Install E Z Steer skags Front end pushes Check for worn skags Check for binding suspension shafts and grease all p...

Страница 165: ...educe 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 a...

Страница 166: ...if necessary SEE YOUR DEALER Harsh drive clutch engagement Drive belt worn or too narrow Excessive belt sheave clearance Replace drive belt SEE YOUR DEALER Drive belt turns over Wrong belt for applic...

Страница 167: ...Worn drive belt Excessive belt sheave clearance Loose torque stop Sticky clutch Inspect and replace if necessary SEE YOUR DEALER Inspect and adjust SEE YOUR DEALER Engine doesn t start electric start...

Страница 168: ...perate satisfactori ly when dried Running too lean a mixture too small a main jet will cause seizure resulting in loss of power SEE YOUR DEALER This indi cates a major engine problem that must be repa...

Страница 169: ...167 NOTES...

Страница 170: ...168 NOTES...

Страница 171: ...169 SECTION 9 WARRANTY Service And Warranty Information 170 Warranty 171 173 Polaris Extended Service Contract 174 175 Section 9 contains specific warranty information...

Страница 172: ...anty will aid in notification of recovered units to their proper owner Obtaining Service and Warranty Assistance Read carefully and understand the service data and the Polaris warranty contained in th...

Страница 173: ...TRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registrat...

Страница 174: ...cts in parts components or snowmobile due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not c...

Страница 175: ...ervice you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original s...

Страница 176: ...ris Star Card Conditions DThe Polaris Extended Service Contract must be purchased within 90 days from the date of the unit s registration DEach repair visit it subject to a 50 00 deductible DThe Exten...

Страница 177: ...s stator plate and sensors Wiring and other electrical components are ex cluded from coverage DOil injection system coverage is limited to the control module sen sors solenoids pump and throttle cable...

Страница 178: ...ooling System 121 123 Brake Bleeding 127 Brake Components 125 Brake Fluid Replenishment 126 Brake Inspection Hydraulic 124 Brake Lever Travel 67 68 125 128 Brake Lever Mechanical 128 Brakes 67 68 Bulb...

Страница 179: ...r 54 Indy Select Rear 55 Inspection Hydraulic Brakes 124 Inspection Steering 144 Inspection Track 143 Inspection Water Pump Belt 115 Installing the Side Bulbs 131 Lighting Check 71 Liquid Cooled Model...

Страница 180: ...rive System 150 Controls and Linkage 149 Electrical Connections 151 Track and Suspension 152 Supplies 139 Surge Tank 122 123 Suspension Adjustment Features 44 Suspension Adjustment EDGE RMK 50 Suspens...

Страница 181: ......

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