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MAINTENANCE

Clutch System

Drive Belt Condition

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. See Drive Belt Troubleshooting on page

103.
For improved drive-away during extremely cold temperatures, remove

the belt and warm it to room temperature. Reinstall it before starting the

snowmobile.

Drive Belt Removal

NOTICE:

Do not attempt to remove the drive belt after operating in reverse. The

snowmobile must be stopped after forward motion to prevent damage

to components during belt removal.

1. Stop the engine after operating in a forward motion.
2. Turn the ignition key off. Wait for the engine to come to a complete

stop.

3. Lock the parking brake.
4. Open the hood.
5. Remove the left side panel.
6. Locate the L-wrench in the tool kit. Install the wrench into the open

threaded hole in the outer sheave of the clutch.

7. Turn the wrench clockwise until the sheaves open far enough to

remove the belt.

Содержание 500 IQ Shift

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Страница 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...

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

Страница 5: ...n 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 publicati...

Страница 6: ...of your snowmobile s controls and features The Perfect Fit 28 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 40 This secti...

Страница 7: ...___________________________________ Key Number ___________________________________________________________ Important Notes for Owners and Drivers After reading this manual store it in the snowmobile f...

Страница 8: ...rm to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound...

Страница 9: ...rsonal 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...

Страница 10: ...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 as d...

Страница 11: ...n off the igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation WARNING Serious injury can occur if fingers or cloth...

Страница 12: ...and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed b...

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

Страница 14: ...r in inclement weather Always observe all laws governing snowmobile operation and speed limits Always be alert and pay attention to the trail ahead Multiplying speed MPH by 1 5 will equal the approxim...

Страница 15: ...wn out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or high ways Steep embankments may also hide your view Always leave yourself a w...

Страница 16: ...lope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in moun tain...

Страница 17: ...erfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Driving on Slippery Surfaces WARNING Never attempt an...

Страница 18: ...to help slow the machine and keep it from rolling freely downhill WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may res...

Страница 19: ...balance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If...

Страница 20: ...g may disrupt this pre cision 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 th...

Страница 21: ...ive wear and damage to the slide rail track and or engine If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the thr...

Страница 22: ...s 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 spin...

Страница 23: ...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...

Страница 24: ...als on the snowmobile If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number i...

Страница 25: ...tunnel Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death No Passenger Warning The NO PASSENGER warning decal is on t...

Страница 26: ...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 electric reverse Machine stopped...

Страница 27: ...d 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...

Страница 28: ...d 4 Handlebar 5 Seat 6 Taillights 7 Rear Bumper 8 Snow Flap 9 Console Storage Compartment if equipped 10 Suspension 11 Track 12 Skis 13 Nosepan 14 Front Bumper do not use for pulling or dragging the s...

Страница 29: ...Headlight Adjuster 5 Speedometer 6 Engine Stop Switch 7 Choke Lever 8 Ignition Switch 9 Brake Lever 10 Parking Brake 11 Handlebar Grip Warmer Switch 12 Thumbwarmer Switch 13 Electronic Reverse Button...

Страница 30: ...el 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 the fuel supply Adjustable Headlights Ad...

Страница 31: ...ns We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The machine should be methodically tested one change at a time under the same...

Страница 32: ...one inch of pre load beyond the 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 r...

Страница 33: ...nts involve a compromise or trade off For example a suspension set up for snowcross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bottom out harshly on...

Страница 34: ...on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are available from your dealer Polaris offers track kits for improved flotati...

Страница 35: ...ard on the seat and bounce 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 mea...

Страница 36: ...rmer 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 pre...

Страница 37: ...oupling and the Front Rear Scissor Stop FRSS This type of coupling is available as an accessory for your model The front rear scissor stop FRSS couples the movement of the front torque arm with the re...

Страница 38: ...and the front torque arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performanc...

Страница 39: ...st 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 accelerat...

Страница 40: ...oducts on the skis and track must be maintained to obtain proper vehicle control on hard packed snow or ice See your dealer for assistance Accessories Polaris offers a wide range of accessories for yo...

Страница 41: ...hicle when the handle bars are turned fully to the left or right Handlebar Position Follow these steps to adjust handlebar position 1 Remove the handlebar cover 2 Loosen the four upper and four lower...

Страница 42: ...llow these steps to adjust handlebar angle at the handlebar block 1 Remove the handlebar cover 2 Loosen the four upper adjuster block bolts 3 Adjust the handlebar to the desired angle 4 Torque the bol...

Страница 43: ...eering System 44 Recoil Rope 45 Cooling System Seal 73 Parking Brake Lock Brake Lever Brake System 42 43 77 Auxiliary Shut Off Switch Engine Stop Switch 46 Ignition Switch 46 Taillight Brakelight Head...

Страница 44: ...perience n Throttle Lever The throttle and brake are the primary controls of your snowmobile Always make sure both are functioning properly Squeeze the throttle lever to make sure it compresses evenly...

Страница 45: ...tes low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 79 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed che...

Страница 46: ...y 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...

Страница 47: ...ich could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle Use of traction products such as studs increases the possibility of tr...

Страница 48: ...mstances should your snowmobile be operated with the hood open or removed Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowm...

Страница 49: ...ne Pull it up to allow restarting n Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF n Tether Switch if equipped If your machine has a tether switch remove the teth...

Страница 50: ...not operate the electric starter or pull rope starter while the engine is running NOTICE Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Da...

Страница 51: ...s 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...

Страница 52: ...e See page 98 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 incomp...

Страница 53: ...y or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up of the engine drive train and track 1 Use an appropriate stand to securely sup po...

Страница 54: ...ng 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 Never start the engine or let it run in an enclo...

Страница 55: ...fuels for your machine Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of...

Страница 56: ...ld result in engine damage This is especially important when the machine is operated in mountainous ter rain NOTICE Operating the snowmobile without adequate engine lubrication can result in serious e...

Страница 57: ...e performance A lean mixture may be caused by things like fuel line restrictions for eign matter in the carburetor or clogged fuel filters A rich mixture may be caused by snow build up on the pre filt...

Страница 58: ...ain jet installed in production is not correct for all altitudes and or temperatures See page 74 for more information NOTICE A main jet that s too small will cause a lean operating condition and may c...

Страница 59: ...e safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a carburetor throttle system malfunction immediately...

Страница 60: ...throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 If the engine doesn t start take the snowmobile to an authorized Polaris dealer for service Ex...

Страница 61: ...ter 45 sec onds in reverse This feature protects the engine from overheating and will reset when it is shifted into forward or when the engine is stopped and restarted WARNING Improper reverse operati...

Страница 62: ...started Disengaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Push the yellow reverse button for one second and release The engine will slow and and begin to rotate forward The light...

Страница 63: ...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...

Страница 64: ...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...

Страница 65: ...rvals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty perio...

Страница 66: ...C 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 Alignment Offset without belt 82 I I I Drive Belt Condition 8...

Страница 67: ...AGEMENT Pilot Air Screws I I I Carburetor synchronize 74 I I I Idle RPM I I I Throttle Lever 57 I I I I I Oil Pump Lever synchronize I I I Throttle Cable 67 L L L Choke Cable 67 L L L Choke 67 I I I V...

Страница 68: ...nsion Shock Oil I I I I Cooling System 73 I I I I Drive Shaft Bearing 67 L L L I Jackshaft Bearings 96 L L L I Skags Wear Bars 93 I I I I I Ski Saddle Spindle Bolts I I I I I Steering Arm s I Drive Ch...

Страница 69: ...n pivot shafts with Polaris Premium All Season Grease at 500 miles 800 km initially every 1000 miles 1600 km after that and before off season storage each year Lack of lubrication will adversely affec...

Страница 70: ...re than four 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 Choke Cable Lub...

Страница 71: ...sight glass 2 Change the chaincase oil after the first 500 miles 800 km then every 1000 miles 1600 km or seasonally Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 98 for the...

Страница 72: ...from the plug 4 Install a new sealing washer on the drain plug Tip The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 5 Reinstall the drain p...

Страница 73: ...embly process Avoid prolonged idle speeds which cause plug fouling and carbonization Use recommended spark plugs with the proper gap Use only resistor type spark plugs Torque spark plugs to 18 22 ft l...

Страница 74: ...arburetor throttle body 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 electrode...

Страница 75: ...nomy or carburetor mal function Always reinstall the intake filters before operating the snowmobile Oil Lines Inspect oil line condition every 1000 miles 1600 km Oil Filter The oil filter is located a...

Страница 76: ...kinked replace it promptly n Cooling System Inspect the fan intake and outlet edge seal at the input and output for cracks loosening of duct and blockage or obstructions Make any neces sary repairs pr...

Страница 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...

Страница 78: ...r Always work in a well ventilated area away from anything that may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the fuel warnings on page 51 Cleani...

Страница 79: ...move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut 1 3 Finger tighten the adjuster bolt 2 until it...

Страница 80: ...eath 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 pads when the brake pad mater...

Страница 81: ...h a plastic sight glass in the brake reservoir If the fluid is sufficient the sight glass will be black If the sight glass is any color other than black add brake fluid Keep the master cylinder cover...

Страница 82: ...2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16I 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...

Страница 83: ...from the housing 4 With the wire harness 2 attached to the bulb 3 with draw the bulb from the housing 5 Grasp the bulb by its metal base and carefully separate the bulb from the harness Headlight Bulb...

Страница 84: ...lacement 1 Remove the screws securing the taillight lens Remove the lens 2 Push the bulb inward and turn it counterclockwise to remove it 3 Install a new bulb Push the bulb inward and turn it clockwis...

Страница 85: ...by an autho rized 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 clutches are m...

Страница 86: ...Reinstall it before starting the snowmobile Drive Belt Removal NOTICE Do not attempt to remove the drive belt after operating in reverse The snowmobile must be stopped after forward motion to prevent...

Страница 87: ...ockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the L wrench and store it in the tool kit 4 Reinstall the side panel 5 Close and secure the hood Drive B...

Страница 88: ...the clutch see page 83 Turn the wrench clockwise slightly to remove pressure from the sheaves 2 Loosen the 7 16I jam nut 3 Using a 1 8I Allen wrench turn the set screw inward clockwise to increase the...

Страница 89: ...death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and support the rear of the snow mobile off the ground 2 Rotate the track by hand to chec...

Страница 90: ...er surfaces that have little or no snow for lubrication The slide rail needs snow for lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in l...

Страница 91: ...tension and alignment Tip Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the machine and safely support it off the ground 3 Pl...

Страница 92: ...e equal adjust ment on both sides of the track 8 Repeat the measurement on the other side of the track Tip Check more frequently when the machine is new 9 Start the machine and slowly rotate the track...

Страница 93: ...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 r...

Страница 94: ...91 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary...

Страница 95: ...dealer With 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 measure...

Страница 96: ...vehicle control may result causing serious injury or death Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their ori...

Страница 97: ...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 bol...

Страница 98: ...g the useful life of many components See page 98 for the part numbers of Polaris products Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood chassis and plastic...

Страница 99: ...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 instruction...

Страница 100: ...sion 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 snowmob...

Страница 101: ...5 l Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 95 l 2872951 Synthetic Chaincase Lubricant 12 oz 355 ml Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 8...

Страница 102: ...narrow Replace the drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for appli cation Replace the drive belt Clutch alignment out of spec Adjust alignment of...

Страница 103: ...ve clearance SEE YOUR DEALER Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Engine doesn t turn Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fu...

Страница 104: ...veral times may be necessary to change plug s Poor engine com pression Mixture is too lean A main jet that is too small will cause seizure result ing in loss of power This indicates a major engine pro...

Страница 105: ...ck ski alignment see page 92 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Set static sag s...

Страница 106: ...atures Check for snow ingestion Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break...

Страница 107: ...ontained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the fol lowi...

Страница 108: ...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...

Страница 109: ...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...

Страница 110: ...present your copy of the Warranty Registration form to the dealer The cost of transpor tation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling deale...

Страница 111: ...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...

Страница 112: ...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...

Страница 113: ...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...

Страница 114: ...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...

Страница 115: ...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...

Страница 116: ...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...

Страница 117: ...114 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Страница 118: ...115 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Страница 119: ...rive Away 17 Controls and Linkage 95 Coolant 73 Cooling System 73 Customer Service 104 D Disabled Operators 11 Drive Belt 17 84 Drive Belt Adjustment 85 Drive Belt Condition 83 Drive Belt Deflection 8...

Страница 120: ...ear Rear Scissor Stop 35 Rear Suspension Adjustments 30 36 Rear To Front Coupling 35 Recoil Rope 45 Recommended Maintenance 7 Registration Warranty 106 Reverse 58 59 Reverse Warning 23 Rider Capacity...

Страница 121: ...for Storage 97 Track Inspection 86 Track Lubrication 87 Track Maintenance 86 90 Track Safety 8 Track Tension 31 88 Track Warm Up 50 Track Warning 22 Traction Products 37 Transporting the Snowmobile 97...

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