7INTRODUCTIONImportant Notes for Owners and DriversAfter reading this manual, store it in the snowmobile for convenientreference. It should remain wit
312456797MAINTENANCEGeneral MaintenanceTool KitA tool kit is included witheach machine for emergencyand routine maintenance.Always keep the tool kit w
A98MAINTENANCETrack MaintenanceTrack InspectionWARNINGBroken track rods are a serious safety hazard. They can cause arotating track to come off the ma
99MAINTENANCETrack MaintenanceWARNINGMoving parts can cut and crush body parts. When performing thechecks and adjustments recommended on the following
100MAINTENANCETrack MaintenanceTrack TensionIf the track needs adjustment:5. Loosen the rear idler shaftbolt (D).6. Loosen the locknuts (A).7. Tighten
A101MAINTENANCETrack MaintenancenTrack AlignmentPeriodically check that the trackis centered and running evenlyon the slide rails. Misalignmentwill ca
++++102MAINTENANCESteering SystemSteering Inspection and AdjustmentEach week, or before a long ride, check all steering system fastenersand tighten if
XY10″10″103MAINTENANCESteering SystemSki AlignmentWARNINGImproper ski alignment or adjustment may cause loss of steeringcontrol, resulting in serious
A104MAINTENANCESteering SystemnSki SkagsWARNINGWorn skis and/or skags will adversely affect handling. Loss ofvehicle control may result, causing serio
A7/16″(1.1 cm)105MAINTENANCESuspension MaintenancenSlider WearMeasure slider thickness atseveral points along therail. Have your dealerreplace the sli
106MAINTENANCESuspension MaintenanceExtended StorageOff-season or extended storage of your snowmobile requires preventivemeasures to aid against deter
8INTRODUCTIONPreservation of the EnvironmentPolaris i s committed t o supporting an environmental educationcampaign. We encourage state and provincial
107MAINTENANCEExtended StorageBearingsGrease the jackshaft and drive shaft clutch side bearings with PolarisPremium All-Season Grease or a similar hig
108MAINTENANCEExtended StorageElectrical ConnectionsReplace worn or frayed electrical wire and connectors. Be sure wiringharness is properly secured a
109POLARIS PRODUCTSPart No. DescriptionEngine Lubricants2870791 Fogging Oil (12 oz. Aerosol)2871098 Premium 2-Cycle Engine Oil (qt.)2871097 Premium 2-
110TROUBLESHOOTINGEngine TroubleshootingCAUTION: Unless you have experience and training in two-cycleengine repair, see your dealer if technical probl
111TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionNoise in drivesystemBroken drive clutchcomponentsS SEE YOUR DEALER.Bearing fail
112TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionEngine turnsbut fails to startFaulty ignition S Install new spark plug(s). If e
113TROUBLESHOOTINGSuspension TroubleshootingProblem Solution (perform only one change at a time)Rear suspensionbottoms too easily- Verify sag dimensio
114TROUBLESHOOTINGBelt TroubleshootingBelt Wear/Burn DiagnosisCauses SolutionsDriving at low RPM S Drive at higher RPMs. Gear the machine down. Checkb
115WARRANTYService And Warranty InformationObtaining Service and Warranty AssistanceRead and understand the service data and the Polaris warrantyinfor
116WARRANTYLimited WarrantyPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-ITED WARRANTY on all components of the Polar
9INTRODUCTIONVehicle Identification NumbersRecord your snowmobile’s identification numbers and key number inthe spaces provided. Remove the spare key
117WARRANTYLimitations of warranties and remediesALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-PLIED WARRANTIES OF MERCHANTABILITY AND F
118WARRANTYConditions and ExclusionsIn order to qualify for warranty, the product must have been properly set up and tested bya Polaris Dealer (if app
119WARRANTYPolaris Second Year Engine Service ContractSecond Year Engine Service Contract is standard on all eligible new and unusedsnowmobiles that w
120WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL
10SAFETYOperator SafetyThe following signal words and symbols appear throughout thismanual and on your vehicle. Your safety is involved when these wor
11SAFETYOperator SafetyFollow the recommended m aintenance program outlined beginning onpage 72 of this manual t o ensure that all critical components
12SAFETYOperator SafetyStay Clear of TrackYour snowmobile is propelled by a revolving track that must bepartially exposed for proper operation.WARNING
13SAFETYOperator SafetySurvival PreparationFor your safety, always ride i n a group of other snowmobilers. Alwaystell someone where you’re going and h
14SAFETYOperator SafetyDisabled OperatorsSafe operation of t his rider-active vehicle requires good judgement andphysical skills. Operators with cogni
15SAFETYOperator SafetyDriver AwarenessSlow down when traveling near poles,posts, or other obstacles. Be especiallyalert if you’re snowmobiling after
16SAFETYOperator SafetyAvalanch esSnowmobilers should always be properlytrained and equipped before traveling inmountainous terrain:S Take an avalanch
17SAFETYOperator SafetyIce and Snow Build-upWARNINGIce and snow build-up may interfere with the steering of yourmachine, resulting in serious injury o
18SAFETYOperator SafetyDriving in Hilly TerrainWARNINGClimbing a hill or crossing the face of a slope may result in loss ofbalance and machine roll-ov
19SAFETYOperator SafetyDrive BeltDo not operate the engine with the drive belt removed.Any servicing that requires operation without a belt must be pe
20SAFETYOperator SafetyInadequate Snow ConditionsWARNINGDo not drive for prolonged periods on blacktop, gravel, or ice.Doing so could cause irreversib
21SAFETYOperator SafetyDriving ResponsiblyEvery snowmobile handles differently, and even the most docileconditions may become dangerous if operators d
22SAFETYOperator SafetyWindchill/Temperature ChartsThe following information is provided to help you determine whentemperatures become dangerous for r
23SAFETYSafety Decals and LocationsWarning decals have been placed on the snowmobile for yourprotection. Read and follow the instructions of the decal
+24SAFETYSafety Decals and LocationsTrack WarningStay clear of track. Do not sit onseat back. Entanglement with thetrack or a fall from seat back mayr
25SAFETYSafety Decals and LocationsReverse WarningThe reverse warningdecal is located on theconsole below thewindshield:Reverse operation,even at low
26SAFETYSafety Decals and LocationsS To avoid serious injury ordeath, read and understand allwarnings and the Owner’sManual before operation. If thema
WARNINGWARNINGRead, understand, and follow all of the instructionsand safety precautions in this manual and on allproduct labels.Failure to follow the
104321146812111315975727FEATURES1. Hood2. Headlight3. Windshield4. Handlebar5. Side Shield6. Seat7. Storage Compartment8. Taillights9. Rear Bumper10.
28FEATURES1. Fuel Filler Cap2. Ignition Switch3. Handlebar hook4. Brake Lever5. Mountain Bar6. MFD(Multi--Function Display)7. Engine Stop Switch8. Thr
29FEATURESRIDER SELECT Adjustable Steering SystemThe RIDER SELECT adjustable steering system allows you to adjustthe handlebar position to fit your st
1130FEATURESSeat Storage CompartmentLift the seat lever (1)and lift the seat to accessthe under-seat storage area.Adjustable HeadlightsAdjust the head
31FEATURESDetonation Elimination Technology (D.E.T.)A detonation sensor monitors the engine and responds to detonation byautomatically reducing the en
32FEATURESInstrumentationMFD Component IdentificationItem1 Analog Gauge2 Digital Gauge3 Check Engine Indicator4 Low Oil Indicator5 High Temp Indicator
33FEATURESInstrumentationMFD SettingsWith the engine running, use theMFD Control Switch (1) to set theMFD display to your preference.The rocker switch
34FEATURESInstrumentationMFD Digital Display ProgramsPress the MODE button to cycle through the three MFD programs:Performance, Engine and History. Ea
35FEATURESInstrumentationMFD Digital Display ProgramsPerformance ProgramClock Setting1. While in the CLOCK display, pressand hold the SET button for f
36FEATURESInstrumentationMFD Digital Display ProgramsAltitude (if equipped)The rider can calibrate the altimeter forcurrent atmospheric conditions. Al
37FEATURESInstrumentationMFD Digital Display ProgramsHistory ProgramThe History Program automatically displays electrical system voltagelevel and fuel
38FEATURESInstrumentationMFD Digital Display ProgramsService Interval ReminderThe gauge logs the number of enginehours between service reminders.When
39FEATURESInstrumentationMFD Battery ReplacementIf the clock function of the MFD isn’tworking properly, replace the battery.Replacement batteries are
40FEATURESInstrumentationGauge Cleaning1. Wipe the gauge face as needed using a clean cloth and a mild soapand water solution. Wipe dry with clean, so
124341THE PERFECT FITIQ Front Suspension AdjustmentsBreak in the suspension for approximately 150 miles (240 km) beforemaking any fine-tuning adjustme
1234542THE PERFECT FITIQ Front Suspension AdjustmentsWARNINGAlways verify ski alignment before making adjustments to theIFS. See page 103 to check ali
A43THE PERFECT FITIQ Front Suspension AdjustmentsShock Compression Damping (Standard Only)Adjustments to the compression stiffness of IndySelect shock
CB44THE PERFECT FITIQ Front Suspension AdjustmentsFront Shock Spring Preload (Premium Only)Increasing spring preload will increaseski-to-ground pressu
45THE PERFECT FITIQ Front Suspension AdjustmentsShock Valving (Premium Only)Some shocks can be revalved if spring preload alone isn’t sufficientand fu
46THE PERFECT FITIQ Rear Suspension AdjustmentsRider weight, riding style, t rail conditions, and vehicle speed all affectsuspension action.Each rear
2Copyright 2004 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat
47THE PERFECT FITIQ Rear Suspension AdjustmentsRear Suspensio n Initial Spring Preload Setting(Sag Method)To set up t he rear suspension torsionspring
48THE PERFECT FITIQ Rear Suspension AdjustmentsRear To rsion Spring TensionTo adjust rear torsion spring tension, rotate the three-position camusing t
A49THE PERFECT FITIQ Rear Suspension AdjustmentsRear ShocksIndy Select Rear ShockSome snowmobiles are equipped with the Indy S elect rear shock,which
A50THE PERFECT FITIQ Rear Suspension AdjustmentsRear ShocksAR VIN Rapid Adjust ShockThe ARVIN Rapid Adjust shock is available as an option on somemode
51THE PERFECT FITHandlebar AdjustmentsHandlebar PositionUse the RIDER S ELECT feature to adjust handlebar position. Seepage 29.Handlebar AngleFollow t
52THE PERFECT FITAccessoriesPolaris offers a wide range of accessories for your snowmobile to helpmake each ride more enjoyable.NOTE: The accessory te
53PRE-RIDE INSPECTIONSPre -Ride ChecklistInspect all items on the checklist for proper operation or conditionbefore each use of the snowmobile. Proced
54PRE-RIDE INSPECTIONSBefore Starting the EngineWARNINGWorn, damaged, or malfunctioning components may causeserious injury or death. Before starting t
55PRE-RIDE INSPECTIONSBefore Starting the EnginenBrakesAlways check thefollowing items for properoperation before startingthe engine.Brake Lever Trave
431256PRE-RIDE INSPECTIONSBefore Starting the EnginenPark Brake L ever Lo ckUse the park brake l ever lock only when you want the machine toremain sta
3WELCOMEThank you for purchasing a P olaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of util
57PRE-RIDE INSPECTIONSBefore Starting the EnginenHood LatchesThe hood of the snowmobile protects t he operator from moving partsas well as aiding in s
58PRE-RIDE INSPECTIONSStart the Engine and Checkn Engine Stop Switch: Check the auxiliary shut-off switch forproper operation. Push the switch down to
59OPERATIONStarting the EngineWARNINGBefore starting the engine, always refer to all safety warningspertaining to snowmobile operation. Never start yo
60OPERATIONEngine Break-InNo single action on your part is as important to long, trouble-freemachine life as proper break-in of a new or rebuilt engin
61OPERATIONEngine Break-InOil Injection SystemAlways fill the oil reservoir when refueling.CAUTIONSerious engine damage can occur without the proper l
62OPERATIONTrack Warm-UpWARNINGA loose track or flying debris could cause serious injury or death.Stand clear of the front of the machine and the movi
63OPERATIONSlide Rail and Track CoolingCAUTIONInadequate cooling and lubrication will lead to overheating of theslide rail and track, resulting in pre
64OPERATIONFuelWARNINGGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling gasoline.
65OPERATIONFuelFor peak performance, Polaris recommends the use of 91 octane orhigher fuel. Although 87 octane fuel is usable, some engineperformance
66OPERATIONOilnLow Oil Indicator LightThe low oil indicator light will alert the operator if the oil level is low.Visually check the oil level in the
67OPERATIONn Engine Stop SwitchPush down on the engine stopswitch (A) to ground out theignition and stop the enginequickly. Pull the switch up to theO
68OPERATIONThrottle LeverWARNINGAn improperly functioning throttle lever may cause erraticmachine behavior and loss of control, which could result ins
69OPERATIONEmergency StoppingThe following chart lists methods for stopping the snowmobile in theevent of an emergency. See page 67 for more informati
70OPERATIONElectronic Reverse (PERCt)Electronic reverse will activate only if the engine RPM is below 4000.WARNINGImproper reverse operation, even at
71OPERATIONDaily StorageAt the end of each ride, park thesnowmobile on a level surfaceand support it at the rear with anappropriate track stand. Thetr
72MAINTENANCEPolaris Recommended Maintenance ProgramTo ensure many trouble-free miles of snowmobiling enjoyment, followrecommended regular maintenance
73MAINTENANCEPeriodic Maintenance Interval TableThe following chart i s a guide based on average riding conditions. Youmay need to increase frequency
74MAINTENANCEPeriodic Maintenance Interval TableSeePFrequencyItemPage150 mi.(240 km)500 mi.(800 km)1000 mi.(1600 km)2000 mi.(3200 km)Pre-SeasonBrakesH
75MAINTENANCEPeriodic Maintenance Interval TableSeeFrequencyItemPage150 mi.(240 km)500 mi.(800 km)1000 mi.(1600 km)2000 mi.(3200 km)Pre-SeasonCHASSISS
76MAINTENANCEMaintenance LogPresent this section of your manual to your dealer each time yoursnowmobile is serviced. This will provide you and future
5TABLE OF CONTENTSIntroduction 7...This section contains helpful information for owners and drivers andillustrates the loc
77MAINTENANCEMaintenance LogAdditional Services PerformedAuthorized Polaris Servicing DealerServicing TechnicianDate MileageType of ServiceAdditional
++78MAINTENANCELubricationFront SuspensionThe Fusion front suspension and steering components do notrequire lubrication.Rear Suspensio nLubricate the
ABC79MAINTENANCELubricationnChaincase OilCheck the chaincase oil level at the intervals outlined in themaintenance charts beginning on page 73. Mainta
80MAINTENANCEGeneral MaintenanceSpark PlugsA new engine can cause temporary spark plug fouling due to thepreservative added during the assembly proces
281MAINTENANCEGeneral MaintenanceSpark PlugsSpark plug condition is i ndicative of engine operation. The spark plugfiring end condition should be read
1282MAINTENANCEGeneral MaintenanceIntake FilterThe intake foam filter limits snow ingestion into the intake system.When operating in loose powder snow
83MAINTENANCEGeneral MaintenanceFuel InjectorsAll fuel injector service m ust be performed by an authorized Polarisdealer. Do not attempt to clean or
84MAINTENANCEGeneral MaintenanceExhaust SystemCheck the exhaust system for wear or damage at approximately 2000miles (3200 km). To inspect, allow the
85MAINTENANCEGeneral MaintenanceCoolant High Temperature Indicator LightThe high temperature indicator light is controlled by a switch in theECU. If t
86MAINTENANCEGeneral MaintenanceBleeding t h e Cooling SystemUse of a non-standard pressure cap will not allow the recovery systemto function properly
AB87MAINTENANCEGeneral MaintenanceDrive Chain TensionCheck drive chain tension weeklyand before each long trip. To obtaincorrect chain tension:1. Rota
88MAINTENANCEGeneral MaintenancenHydraulic Brake In sp ectio nInspect the brake leverreserve before each use ofthe snowmobile.Firmly depress the brake
89MAINTENANCEGeneral MaintenanceBrake Components1. Brake Caliper2. Brake Disc3. Backing Plate4. Brake Pad Material(Replace when thick-ness is less tha
90MAINTENANCEGeneral MaintenanceBrake FluidWARNINGAfter opening a bottle of brake fluid, always discard any unusedportion. Never store or use a partia
91MAINTENANCEGeneral MaintenanceBleeding the Hydraulic Brake SystemAir in the hydraulic brake system will cause spongy brake lever action.Bleed the sy
21392MAINTENANCEGeneral MaintenanceNOTE: Do not touch a halogen bulb with bare fingers. Oil from skinleaves a residue, causing a hot spot that will sh
A93MAINTENANCEGeneral MaintenanceClutch SystemWARNINGIf you become aware of higher than normal clutch engagement oran unusual vibration or shift patte
A94MAINTENANCEGeneral MaintenancenDrive Belt ConditionPeriodically check the condition and tension of the drive belt, andalways carry a spare. Inspect
95MAINTENANCEGeneral MaintenanceDrive Belt Installation1. Drop the drive belt over thedrive clutch and pull back theslack.NOTE: To ensure satisfactory
AB1.010″-.030″(.25-.75mm)96MAINTENANCEGeneral MaintenancenDrive Belt DeflectionMeasure belt deflection with bothclutches at rest and in their fullneut
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