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WARNING
Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
PROPOSITION 65 WARNING
Snowmobile engines discharge fuel and exhaust, which contain chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm, onto the snow on which they operate. Keep this engine
properly tuned and avoid unnecessary idling and spillage during fueling.
WARNING
The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm.
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WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-
wide family of Polaris enthusiasts. Be sure to visit us online at
www.polarisindustries.com for the latest news, new product introduc-
tions, upcoming events, career opportunities and more.
Here at Polaris we proudly produce an exciting line of utility and recre-
ational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER utility vehicles
• Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-
ational vehicles manufactured in the world today. Many years of experi-
ence have gone into the engineering, design, and development 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'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 interested in your
total satisfaction. Be sure to return to your dealership for all of your ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!
1
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries Inc.
RIDER SELECT is a trademark of Polaris Industries Inc.
M-10 is a registered trademark of FAST Inc.
Copyright 2005 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. Depictions and/or 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, is
expressly prohibited.
Printed in U.S.A.
2006 600 Fusion Owner's Manual P/N 9920057
2
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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
This section contains helpful information for owners and drivers and
illustrates the location of important identification numbers that should
be recorded in the owner's manual.
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
This section describes safe vehicle operation and identifies warning
decals and their locations.
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
This section identifies the locations of your snowmobile's controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 43
This section explains how to tailor the suspension and other features for
an optimum riding experience.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 62
This section explains procedures that must be performed before riding.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
This section defines your role, and your dealer's role, in your snowmo-
bile's regular maintenance.
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 124
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 125
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 138
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3
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INTRODUCTION
Vehicle Identification Numbers
Record your snowmobile's identification numbers and key number in
the spaces provided. Remove the spare key and store it in a safe place.
Your key can be duplicated only by mating a Polaris key blank with one
of your existing keys, so if both keys are lost, the ignition switch must
be replaced.
✪
Vehicle Model Number: ___________________________________________________
Tunnel VIN (✪)(lower right side of the tunnel):__________________________________
Engine Serial Number (on recoil housing): ____________________________________
Key Number: ___________________________________________________________
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient ref-
erence. It should remain with the snowmobile when sold.
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 form is neces-
sary to ensure warranty coverage.
Protect and preserve your right to ride by joining your local trail riding
clubs.
4
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INTRODUCTION
Preservation of the Environment
Polaris is committed to supporting an environmental education cam-
paign. We encourage governments to adopt rigorous safety training pro-
grams that encourage protection of our environment, including wildlife
and vegetation.
Snowmobile clubs and other organizations are working together to pro-
tect our environment. Please support their efforts and operate your
snowmobile with consideration for the protection and preservation of
our environment.
Noise Level
One of the most publicized issues about snowmobiles is noise. The
Society of Automotive Engineers (SAE), the standard-setting body for
snowmobile development, recommends that 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 wel-
come to non-snowmobilers, so you have a responsibility to operate your
snowmobile with concern for others. We do our part by manufacturing
quieter machines; we ask your help to further reduce the impact of noise
by operating your snowmobile safely and responsibly.
Air Pollution
Polaris engineers continuously investigate ways to reduce emission lev-
els of two-stroke engines. We expect our efforts to lead to the reduction
of potential air pollution.
In addition to our technological research, we encourage government
agencies, manufacturers, distributors, dealers, ecologists, and other
interested parties to work together to develop data on environmental
topics.
5
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SAFETY
Operator Safety
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol, on your vehicle or in this manual, alerts you to the
potential for injury.
WARNING
The safety alert warning indicates a potential hazard that may result in serious
injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may result in minor
injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the vehicle.
NOTE
A note will alert you to important information or instructions.
6
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SAFETY
Operator Safety
Follow the recommended maintenance program beginning on page 84
of this manual to ensure that all critical components on the snowmobile
are thoroughly inspected by your dealer at specific mileage intervals.
WARNING
Driving a snowmobile requires your full attention. DO NOT drink alcohol or
use drugs or medications before or while driving or riding as a passenger.
They will reduce your alertness and slow your reaction time.
Snowmobiles are capable of traveling at high speeds. Use extra caution to
ensure operator safety. Make sure your snowmobile is in excellent operating
condition at all times. Always check major and vital safety components
before every ride.
All Polaris snowmobiles are designed and tested to provide safe operation
when used as directed. Failure of critical machine components may result
from operation with any modifications, especially those that increase speed
or power. DO NOT MODIFY YOUR MACHINE. The snowmobile may
become aerodynamically unstable at speeds higher than those for which it is
designed. Loss of control may occur at higher speeds. Modifications may
also create a safety hazard and lead to bodily injury.
The warranty on your entire machine is terminated if any equipment has
been added, or any modifications have been made, to increase the speed or
power of the snowmobile.
7
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SAFETY
Operator Safety
Stay Clear of Track
Your snowmobile is propelled by a revolving track that must be partially
exposed for proper 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 alignment procedures.
Stay Clear of Engine
Never attempt adjustments with the engine running. Turn 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 clothing contact the moving parts of an
engine. Always stop the engine before attempting adjustments.
8
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SAFETY
Operator Safety
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience and the features available on
some snowmobiles, 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 steering control.
WARNING
Improper riding position may reduce control and could result in serious injury
or death. Always ride in a position that allows for control of your vehicle.
Riding Apparel
Be prepared, be warm and be com-
fortable when riding. Be aware of
the weather forecast, especially the
windchill, and dress accordingly.
See the chart on page 20.
WARNING
Avoid wearing loose clothing or
long scarves, which can become
entangled in moving parts and
cause serious injury. Always
wear an approved helmet and
eye protection.
9
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SAFETY
Operator Safety
Survival Preparation
For your safety, always ride in a group of other snowmobilers. Always
tell someone where you're going and how long you expect to be gone. If
it isn't possible to ride with others, and you must travel into remote
areas, always carry survival 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 of building a fire, and a two-way radio or cel-
lular telephone.
For added protection, carry the following items on your snowmobile at
all times:
• Spare Drive Belt
• Extra Set of Spark Plugs
• Tow Rope
• Winter Survival Kit
• Trail Map
• Owner's Manual
• First Aid Kit
• Tool Kit
• Extra Oil
• Fuel Deicer
10
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SAFETY
Operator Safety
Disabled Operators
Safe operation of this rider-active vehicle requires good judgement and
physical skills. Operators with cognitive or physical disabilities have an
increased risk of loss of control, which could result in serious injury or
death.
Rider Capacity
Your Polaris snowmobile is designed for a single rider only. Do not
carry a passenger.
Excessive Speed
WARNING
High speed driving, especially at night, could result in serious injury or death.
Always reduce speed when driving at night or 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 approximate number of feet per sec-
ond your machine travels. If your speed is 40 MPH, your machine is
traveling about 60 feet per second. If you look back for only two sec-
onds, 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.
11
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SAFETY
Operator Safety
Driver Awareness
Slow down when traveling near poles,
posts, or other obstacles. Be especially
alert if you're snowmobiling after dark.
Always be on the alert for wire fences.
Single strands are especially dangerous,
since there may be a great distance
between posts. Guy wires on utility poles
are also difficult to distinguish.
Make sure the way is clear before crossing
railroads and other roads and highways.
The noise of your machine will drown 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 way
out.
R R
Variances in snow depth and/or water currents may result in uneven ice
thickness. You may drown if you break through the ice. Avoid travel-
ling on frozen bodies of water.
When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver's training and
safety courses.
12
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SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly
trained and equipped before traveling in
mountainous terrain:
• Take an avalanche class
• Travel with experienced people
• Travel on designated trails
• Make sure each person is equipped
with a shovel, probe and avalanche
beacon.
You don't have to be snowmobiling on a slope for an avalanche to occur.
Be aware that all of the snow 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.
For more information about avalanche training and avalanche condi-
tions, contact local law enforcement in your area, or visit either the
American Avalanche Association online at www.americanavalancheas-
sociation.org or the U.S. Forest Service National Avalanche Center at
www.avalanche.org.
13
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SAFETY
Operator Safety
Ice and Snow Build-up
WARNING
Ice and snow build-up may interfere with the steering of your machine, result-
ing in serious injury or death. Keep the underhood area free of snow and ice.
Before driving, manually turn the skis to the left and right to be sure ice
and snow are not interfering with full left and right steering. If difficulty
is encountered, remove ice and snow build-up that may be obstructing
the steering linkage.
NOTE: If your snowmobile is equipped with RIDER SELECT, perform
this check in both the full up and full down steering positions.
Driving on Slippery Surfaces
WARNING
Never attempt an abrupt change of direction when operating on slippery sur-
faces. Proceed slowly and use extra caution.
Driving on ice or hard-packed snow reduces steering and braking control,
which may result in loss of control and serious injury or death. Slow down
and use extra caution when operating on slippery surfaces.
14
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SAFETY
Operator Safety
Driving Downhill
When riding downhill, shift your weight to the rear of the machine and
reduce your speed to a minimum. Apply just enough throttle to keep the
clutch engaged, allowing the engine's compression 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 result in brake failure.
Excessive or repetitive use of the brakes for high speed stops will also cause
an overheated brake system. This condition may lead to a sudden loss of
brakes and/or fire and may result in serious injury or death.
15
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SAFETY
Operator Safety
Driving in Hilly Terrain
WARNING
Climbing a hill or crossing the face of a slope may result in loss of balance
and machine roll-over, causing serious injury or death. Use caution and good
judgement when driving in hilly terrain.
Use extra caution when operating in hilly terrain. If climbing a hill is
unavoidable, keep your weight low and forward. If you must cross the
face of a slope, keep your weight on the uphill side of the machine to
maintain proper 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 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 downhill. Remount the machine, restart the
engine, release the parking brake, and descend the hill carefully.
16
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SAFETY
Operator 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 injury or damage to the engine.
Intake Silencer
Do not operate the engine with the intake silencer or filter removed.
Damage to the engine may occur if the intake silencer or filter are
removed.
Clutches
Do not attempt to service the clutches.
All clutch service must be performed by your dealer. The clutch is a
complex mechanism that rotates at high speeds. Each clutch is dynami-
cally balanced before installation. Any tampering 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 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.
Maneuverability
While much control and maneuverability is achieved through the steer-
ing system and skis, maximum control is achieved by the shifting of
your body weight. Maneuverability will change for lighter operators or
machines designed to carry a load.
17
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SAFETY
Operator Safety
Inadequate Snow Conditions
WARNING
Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could
cause irreversible track damage and lead to serious injury.
Since snow provides the only lubrication for the power slide suspension
and, on liquid cooled models, cooling for the engine, adequate snow
cover is a requirement for operation of your machine. Driving in too lit-
tle snow will result in excessive 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
throttle is opened, the snowmobile will be able to climb up and over the
snow.
CAUTION
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 conditions, see your dealer for an optional wheel kit
that will reduce the wear from overheating.
18
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SAFETY
Operator Safety
Driving Responsibly
Every snowmobile handles differently, and even the most docile condi-
tions may become dangerous if operators drive improperly. If you're
new to snowmobiling, acquaint yourself with the machine and with
what it will and won't do under various conditions. Even seasoned driv-
ers should spend some time getting the feel for a machine before
attempting ambitious maneuvers.
• A snowmobile depends on the rider's body position for proper bal-
ance in executing turns, traversing hills, etc. Always start on a
smooth, level area to begin building your operating experience.
• Before allowing someone else use your snowmobile, know the extent
of their operating skills. Check to see if they've taken a snowmobile
safety 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.
• Don't "jump" your snowmobile. Jumping may injure your back
because of spinal compression. The seat and suspension of your
snowmobile have been designed to provide protection under normal
riding conditions. Your snowmobile is not intended for this kind of
use.
• Be courteous to oncoming traffic by dimming your headlights and
reducing your speed.
• When traveling in a group of snowmobiles, don't tailgate (follow too
closely). Leave enough distance between snowmobiles to provide
ample stopping room and to provide protection from flying snow and
debris. Allow even more distance when driving on slippery surfaces
or when driving in darkness or other low visibility conditions. Be
aware of any snowmobile traffic around your vehicle. Drive defen-
sively to avoid accidents.
• Remove the key from the ignition when you leave the snowmobile
unattended.
19
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SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when tem-
peratures become dangerous for riding.
WIND CHILL CHART (_F)
Estimated Wind
Speed in MPH
Actual Thermometer Reading (_F)
10 -10 -20 -30
Equivalent Temperature (_F)
50
40
30
20
0
-40
-50
-60
Calm
5
50
48
40
36
32
30
28
27
26
40
37
28
22
18
16
13
11
10
30
27
16
9
20
16
10
6
0
-10
-15
-33
-45
-53
-59
-63
-67
-69
-20
-26
-46
-58
-67
-74
-79
-82
-85
-30
-36
-58
-72
-82
-88
-94
-98
-100
-40
-47
-50
-57
-60
-68
-5
10
15
20
25
30
35
40
4
-9
-21
-36
-39
-44
-48
-49
-53
-70
-83
-95
-5
-18
-25
-29
-33
-35
-37
-85
-99
-112
-124
-133
-140
-145
-148
4
-10
-15
-18
-20
-21
-96
-110
-118
-125
-129
-132
0
-104
-109
-113
-116
-2
-4
-6
Wind Speeds
Greater Than
40 MPH Have
Little Added
Effect
Little Danger
(For Properly
clothed Person)
Increasing
Danger
Great
Danger
Danger of Freezing Exposed Flesh
WIND CHILL CHART (_C)
Estimated Wind
Speed in KPH
Actual Thermometer Reading (_C)
5
0
-5
-10
-15
-20
-25
-30
-35
-40
Equivalent Temperature (_C)
0
5
1
0
-5
-10
-16
-23
-28
-32
-34
-35
-36
-15
-22
-29
-35
-39
-41
-43
-44
-20
-27
-36
-42
-47
-49
-51
-52
-25
-33
-42
-48
-53
-57
-59
-60
-30
-38
-48
-55
-61
-64
-66
-68
-35
-45
-54
-63
-69
-73
-75
-76
-40
-50
-61
-69
-76
-80
-82
-84
10
20
30
40
50
60
70
-4
-11
-17
-21
-24
-26
-27
-28
-4
-9
-7
-13
-16
-18
-19
-20
-9
-11
-12
-13
Wind Speeds
Greater Than 70
KPH Have Little
Added Effect
Little Danger
(For Properly
Clothed Person)
Increasing
Danger
Great
Danger
Danger of Freezing Exposed Flesh
20
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SAFETY
Safety Decals and Locations
Warning decals have been placed on the snowmobile for your protec-
tion. Read and follow the instructions of the decals and other warnings
on the snowmobile carefully. If any of the decals depicted in this man-
ual differ from the decals on your snowmobile, always read and follow
the instructions of the decals 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 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 plenum/belt guard removed.
Never run engine with drive belt removed.
Never service clutches yourself -- see your dealer.
Pressure Cap Warning
This warning decal is found under the hood on the pressure cap of appli-
cable liquid cooled models:
Do not open hot. Test or replace when changing coolant. Press
down and turn to release cap. 13 PSI
21
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SAFETY
Safety Decals and Locations
Track Warning
The track warning decal is on
the rear of the 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 the console below the
steering post:
WARNING
This vehicle is designed for
operator only.
“NO PASSENGER”
✪
22
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SAFETY
Safety Decals and Locations
Reverse Warning
The reverse warning decal is located
on the console below the wind-
shield:
WARNING
Reverse operation, even at low
speeds, can cause loss of control
resulting in serious injury or
death. To avoid loss of control,
always:
• Look behind before and while
backing up.
• Avoid sharp turns.
✪
• Shift to or from reverse only
when stopped.
• Apply throttle slowly.
NOTE: For more information, see Owner's Manual.
If electric reverse:
• Machine stopped and engine at idle, push yellow button on LH con-
trol to reverse. Flashing light on dash indicates reverse operation.
• Push button again to return to forward.
Operation Warning
The operation warning decal is
located on the console above the
storage compartments. See page
24 for the text.
✪
23
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SAFETY
Safety Decals and Locations
Operation Warning
• To avoid serious injury or death, read and understand all warnings
and the Owner's Manual before operation. If manual is missing, con-
tact a Polaris dealer for a replacement.
• This vehicle is capable of high speeds. Buried objects or uneven
terrain can cause loss of control. Reduce speed and use extreme
caution when operating in unfamiliar terrain.
• Excessive speed, especially at night or with limited visibility, can
result in insufficient time for you to react to terrain changes, to
avoid unexpected obstacles, or to stop safely.
• Never consume alcohol or drugs before or while operating this vehi-
cle.
• In an emergency, push down the Auxiliary Shut-Off Switch, located
on the top of the throttle control assembly, to stop the engine. Then
pull the brake lever to stop.
• Always 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 crossing roads,
steering and braking ability are greatly reduced. Reduce speed and
allow extra space to turn or stop.
• To maintain vehicle control on ice or hard-packed surfaces, you
should have a proper balance of ski carbides to track studs. See
Owner's Manual for proper use of traction products.
• Repeated stops from high speed may cause fading or sudden loss
of braking ability.
• Parking brake may relax when used for long periods. Do not leave
brake engaged for more than five minutes.
• Before starting engine, check throttle, brake, and steering for
proper operation. Make sure hood is latched. Be seated and in posi-
tion to control the vehicle.
Oil injection system: Use unmixed fuel only. Check oil level when
refueling.
24
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FEATURES
4
5
3
6
2
1
7
8
13
12
14
1. Hood
2. Headlight
3. Windshield
4. Handlebar
5. Seat
6. Snow Flap
7. Suspension
8. Track
9. Storage Compartment
10. Rear Bumper
11. Taillights
12. Nosepan
13. Front Bumper
14. Skis
9
11
9
10
25
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FEATURES
6
5
2
4
3
7
8
9
1
17
1
1. Fuel Filler Cap
2. Ignition Switch
3. Brake Lever
15
14
13
12
4. RIDER SELECT
5. MFD Gauge
6. Headlight Adjuster
7. Engine Stop Switch
8. Throttle Control
9. Hood Hold Down Straps
10. Recoil Starter Handle
11. Headlight Dimmer Switch
12. Park Brake
13. Handlebar Grip Warmer Switch
14. Thumbwarmer Switch
15. Electronic Reverse Button
16. MFD Control
11
16
17. Choke Lever
26
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FEATURES
RIDER SELECT Adjustable Steering System
The RIDER SELECT adjustable steering system allows you to adjust
the handlebar position to fit your style of riding.
Setting Position
Riding Style
Comfort
1, 2
Pull the system rearward to one of the first two
positions for all-day trail riding comfort.
Control
3, 4, 5
Move the system to one of the middle three posi-
tions for improved handling and cornering on the
trails.
Attack
6, 7
Push the system forward to one of the last two
positions for easy sitting-to-standing transitions and
maximum agility in rugged terrain.
WARNING
Some aftermarket accessories (including windshields and cargo bags) may
interfere with the handlebar. Such accessories could limit your ability to steer
the vehicle and/or may contact the brake lever. This could lead to loss of
control resulting in serious injury or death. Always be sure that accessories
do not contact the handlebar or brake lever at any steering position and at
any RIDER SELECT position.
27
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FEATURES
RIDER SELECT Adjustable Steering System
WARNING
Attempting to adjust the handlebar position while the snowmobile is moving
could result in loss of control and serious injury or death. Always stop the
snowmobile before attempting to adjust the steering system.
1. Stop the snowmobile.
2. Press the release button and
move the handlebar forward
or rearward to the desired
position.
WARNING
Do not lubricate the RIDER SELECT mechanism. Doing so could cause loss
of control and result in serious injury or death. The RIDER SELECT mecha-
nism is lubricated for life at the factory.
28
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FEATURES
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.
ON
OFF
2. Turn the valve counter-clock-
wise to turn on the fuel supply.
Seat Storage Compartment
Open or close the storage com-
partments with the key.
Adjustable Headlights
Adjust the headlight beam by moving
the adjuster to the left or right.
Radiator Compartment
Access Panel
The access panel is provided for
cleaning debris from the radiator.
29
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FEATURES
Detonation Elimination Technology (D.E.T.)
The DET system prevents damage to the engine from detonation while
developing the maximum power of the engine safely. A detonation sen-
sor monitors the engine and responds to detonation by automatically
reducing the engine timing. This can result in decreased engine RPM
and performance.
The engine is designed to provide maximum power when premium (91
octane) fuel is used. If a lower octane fuel is used, or if the jetting is
incorrect for your altitude, the DET system will retard ignition to pre-
vent detonation.
When the DET system is adjusting the timing, the DET light on the
gauge will flash. In most cases the flashing will be temporary and the
timing will return to normal. If there is intermittent flashing, it’s likely
that the fuel or jetting is incorrect.
In extreme conditions the DET system retards timing and holds it in a
retarded state. The DET light will remain on until the engine is turned
off and restarted.
30
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FEATURES
Detonation Elimination Technology (D.E.T.)
DET Troubleshooting
Use this chart to determine causes and solutions for detonation. If none
of these conditions exists and the sensor remains activated, see your
Polaris dealer for diagnosis.
Possible Cause
Poor quality fuel
Improper engine modifications
Incorrect jetting
Solution
Replace with higher quality fuel
Do not modify the engine
Use the correct jetting for your altitude
Sensor Fail-Safe
The DET includes a sensor fail-safe system to prevent the engine from
damage if the sensor fails, becomes disconnected or is unable to detect
detonation. The rider will experience a loss in power. The sensor must
be reconnected or repaired to regain full power.
NOTE: The DET light will flash six times if the sensor fails or becomes
disconnected.
31
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FEATURES
Instrumentation
MFD Component Identification
Item
2
1
1
2
3
4
5
6
7
8
Analog Gauge
Digital Gauge
DET Indicator
Low Oil Indicator
High Temp Indicator
Brake Indicator
Reverse Indicator
High Beam Indicator
3
8
4
7
5
6
Digital Display Identification
Item
1
RPM or Speed
Altitude (if equipped)
Service Interval
1
2
2
3
Electrical System
Voltage Level
MAX -Maximum MPH/
KPH or RPM
MPH -Miles per hour
KPH - Kilometers per hour
RPM -Engine crankshaft
revolutions per
minute
4
Air Temp (if equipped)
Engine Temp
Degrees Celsius
Degrees Fahrenheit
7
5
5
6
Miles
6
4
Kilometers
3
Hours
Trip 1/Trip 2/Trip F
Service Label
Altitude Label
7
Fuel Level
32
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FEATURES
Instrumentation
MFD Settings
With the engine running, use the
MFD Control Switch to set the MFD
display to your preference. The
rocker switch (✪) has a MODE but-
ton (top) and a SET button (bottom).
Standard vs. Metric
✪
The MFD will display either stan-
dard or metric units of measurement.
While viewing a screen that displays
measurements (MPH, KPH or tem-
peratures), press and hold the MODE switch until the unit of measure-
ment changes (about 10 seconds).
Speedometer/Tachometer
The speedometer and tachometer can be viewed in either the analog or
the digital display. If the analog display is set to show speedometer read-
ings, the digital screen will automatically display the tachometer (option
1). If the analog is set to show the tachometer, the digital screen will
show the speedometer (option 2).
To change preferences, press and hold the MODE button for three sec-
onds. When the button is released, the new setting becomes active and
screen colors change. See table below.
Analog
Display
Digital
Display
Analog
Screen
Digital
Screen
Option
1
Speed
RPM
Blue “mph”
Blue
Backlight
2
RPM
Speed
Red
“X100rpm”
Red
Backlight
33
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FEATURES
Instrumentation
MFD Digital Display Programs
Press the MODE button to cycle through the three MFD programs: Per-
formance, Engine and History. Each program will remain in the display
until another is selected.
NOTE: The analog will always display either MPH or engine RPM
(whichever setting is selected) regardless of the display pro-
gram being viewed.
Performance Program
The Performance Program automatically displays either speed or
tachometer, whichever is opposite the analog display. See page 33. It
also displays electrical system voltage and fuel levels.
While in the Performance mode, press the SET button to cycle through
the odometer, Trip 1, Trip 2, Trip F and Clock settings.
34
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FEATURES
Instrumentation
MFD Digital Display Programs
Trip Settings
Trip 1 and Trip 2 are odometers used to
check fuel mileage or to keep track of
distance traveled.
1. To reset a trip odometer to zero,
enter the Trip 1 or Trip 2 display.
2. Press and hold the SET button for
two seconds.
Trip F automatically displays if the fuel
level is low. The fuel symbol and the last
fuel bar on the MFD gauge will blink
when the fuel level reaches 1/8th tank.
The Trip F odometer records distance
traveled until enough fuel is added to
raise the level above 1/4 tank. The fuel
symbol and the fuel bar will continue to
blink until the fuel level is above 1/4
tank. The Trip F odometer will automat-
ically reset to zero after refueling.
Odometer Setting
The odometer records the vehicle's total
distance traveled since manufacture.
The odometer cannot be reset.
35
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FEATURES
Instrumentation
MFD Digital Display Programs
Performance Program
Clock Setting
1. While in the CLOCK display, press
and hold the SET button for five
seconds.
2. When the hour starts flashing press
the SET switch once to advance
one hour, or press and hold the
SET button to advance the hour
once every 0.2 seconds.
3. Press the MODE button to save the hour and flash the minutes.
4. Set the minutes in the same manner.
5. When finished, press the MODE button to save the new setting.
NOTE: If the MODE button is not pressed within ten seconds, the clock
will automatically save the new entry.
36
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FEATURES
Instrumentation
MFD Digital Display Programs
Engine Program
The Engine Program automatically displays the engine coolant tempera-
ture, engine hours, electrical system voltage level and fuel level. On
machines equipped with altimeter sensor and ambient air temperature
sensors, altitude and ambient air temperature will display as additional
screens in the engine program. Press the SET button to display the
ambient air temperature and altitude screens (if equipped).
Air Temperature (if equipped)
The MFD displays actual air temperature.
Press and hold the MODE switch for ten
seconds to switch between standard and
metric units of measurement.
Hour Meter
The hour meter records the total hours of
engine operation since manufacture. This
meter cannot be reset.
Engine Temperature
A thermometer measures water temperature,
giving an indication of engine temperature.
37
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FEATURES
Instrumentation
MFD Digital Display Programs
Engine Program
Altitude (if equipped)
The rider can calibrate the altimeter for current
atmospheric conditions. Altimeter accuracy
will be +/-300 ft. (91 m) after adjustment.
NOTE: Press and hold the MODE switch for
ten seconds to switch between stan-
dard and metric units of measure-
ment. When "ALt" displays, the program is in the metric mode.
1. Enter the Engine Program and select the altimeter display.
2. Press and hold the SET button for five seconds.
3. When the digits begin to flash, press the SET button once to
advance 50 feet (15 m), or press and hold the button to advance 100
ft. (30 m) every 0.1 seconds. Adjust the altitude display to within 50
ft. (15 m) of current altitude.
NOTE: The gauge reads barometric pressure and allows the rider to
compensate for daily fluctuations in air pressure. The gauge
can adjust the displayed altitude to +/- 1300 ft. (396 m) from the
preset value. It will adjust up to +1300 ft. (396 m) above the
calibrated altitude. Once the +1300 ft. (396 m) offset has been
reached, the next adjustment is -1300 ft. (396 m) from the cali-
brated altitude, and 50 ft. (15 m) will be added to the altitude
each time the SET button is pressed.
4. Press the MODE button to hold the reading at the adjusted value. If
it's not pressed within five seconds, the gauge will automatically
save the new setting.
38
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FEATURES
Instrumentation
MFD Digital Display Programs
History Program
The History Program automatically displays electrical system voltage
level and fuel level.
While in the History mode, press the SET button to view maximum
vehicle speed, maximum engine rpm or the current service interval set-
ting. The gauge automatically logs the maximum speed and engine rpm
even if the History Program is not currently displayed.
The History Program will display the history of the Maximum Speed,
Maximum RPM and Service Interval settings.
Maximum Speed/RPM Reset
While in either the MAX MPH or the MAX
RPM mode, press and hold the SET button
for three seconds to reset the recorded maxi-
mum values for both MPH and RPM. Both
of these values are reset at the same time.
Reset the MAX MPH/RPM values before
each run to obtain accurate readings.
NOTE: Due to electrical noise, the MFD
may occasionally display MAX
MPH/RPM values that are not rep-
resentative of actual values.
39
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FEATURES
Instrumentation
MFD Digital Display Programs
Service Interval Reminder
The gauge logs the number of engine
hours between service reminders.
When the logged hours reaches the
designated service interval (set by the
user), the gauge provides a reminder
that service is due. "SErVCE" will
flash in the odometer area and "ENG"
will flash in the icon area for five sec-
onds each time the vehicle is started until the service reminder is reset.
To reset the reminder at the existing interval:
1. Enter the service interval screen.
2. Press and hold the SET button for ten seconds, continuing to hold
even after the display begins to flash.
3. When the display stops flashing, release the button. The service
interval has been reset.
To reset the reminder at a new interval:
1. Enter the service interval screen.
2. Press and hold the SET button for five seconds, until the hours
begin to flash.
3. Immediately release the button.
4. Press the button again up to five times to advance the reminder in
50-hour increments.
NOTE: The maximum interval is 250 hours.
To disable the service interval reminder, press the SET button once after
reaching 250 hours on the display. The gauge will display "OFF".
40
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FEATURES
Instrumentation
MFD Battery Replacement
If the clock function of the MFD isn't
working properly, replace the battery.
Replacement batteries are available from
your dealer.
1. Remove the plenum from the under-
side of the hood.
2. Locate the black battery compart-
ment. It has a red wire and a brown
wire with a white stripe. It's located
about three inches down the main
harness from the point where the
harness connects to the MFD.
3. Cut the plastic cable tie from the out-
side of the compartment.
4. Carefully cut the bottom of the com-
partment (opposite the wires) to separate the heat-sealed seams.
Squeeze the corners of the compartment inward so the battery is
visible.
NOTE: Note the orientation of the battery before removing it. An incor-
rectly installed battery will not maintain the clock.
5. Using needle-nose pliers, grasp the battery and rotate it slightly so
the leading edge of the battery is raised slightly away from the bat-
tery holder. Pull the battery out gently.
NOTE: The battery will not come out of the holder unless the leading
edge of the battery is raised. Hold the battery compartment,
not the wires, while removing the battery. Pulling on the wires
will separate them from the battery holder.
41
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FEATURES
Instrumentation
MFD Battery Replacement
6. Install a new battery with fingers only.
7. Seal the end of the battery compartment using high strength double-
sided tape between the two compartment halves or high strength
single-sided tape around the outside of the compartment.
8. Make sure the taped seam of the compartment faces the downward
side of the wire harness.
9. Install a cable tie to secure the compartment to the wire harness in
the same location where the previous cable tie was located. Make
sure the battery wires are not stretched tight.
Gauge Cleaning
1. Wipe the gauge face as needed using a clean cloth and a mild soap
and water solution. Wipe dry with clean, soft cloth.
2. Clean the back side of the gauge using a clean cloth and a mild soap
and water solution. Do not remove the electrical connectors or pro-
tective rubber boot. Do not spray the back side of the gauge or the
wire harness with a pressure washer or other water source.
CAUTION
To prevent damage to the lens, do not use alcohol for cleaning. Do not allow
chemicals or sprays to come into contact with the lens. Immediately clean off
any gasoline that splashes on the gauge during refueling.
42
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THE PERFECT FIT
IQ Front Suspension Adjustments
Independent Front Suspension (IFS)
Break in the suspension for about 150 miles (240 km) before making
any fine-tuning adjustments.
Settings will vary from rider to rider, depending on rider weight, vehicle
speed, riding style, and trail conditions. 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 conditions (trail and snow conditions,
vehicle speed, riding position, etc.) after each adjustment until the best
ride is achieved.
IFS Components
1
1. Skis
2
2. Front shocks and springs
3
3. Rod ends
4. A-arms
IFS Adjustment Options
• Front shock spring preload
• Optional springs
• Optional shock valving (if
equipped with RydeFX
shocks)
4
43
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THE PERFECT FIT
IQ Front Suspension Adjustments
Front Shock Spring Preload
The factory preload setting should be appropriate for most riders and
conditions. Please see your Polaris dealer for assistance before attempt-
ing to adjust preload.
Increasing the spring preload too much may adversely affect the han-
dling of the snowmobile and the performance of the rear suspension.
Decreasing the spring preload too much may allow the upper spring
retainer to fall off.
Shock Valving
RydeFX shocks can be revalved if spring preload alone isn't sufficient
and further adjustment is desired to control suspension stiffness.
WARNING
Changing shock valving on RydeFX shocks requires special tools and a
sound knowledge of mechanical theory, tool use, and shop procedures to
perform the work safely and correctly. Shocks contain high-pressure nitro-
gen gas. Use extreme caution when handling high-pressure service equip-
ment. We recommend that this work be performed by a Polaris dealer.
Front Springs
The front springs can be changed if spring preload alone isn't sufficient
and further adjustment is desired to control suspension stiffness. See
your Polaris dealer for more information.
44
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THE PERFECT FIT
Rear Suspension Adjustments
Rider weight, riding style, trail conditions, and vehicle speed all affect
suspension action.
Each rear suspension can be adjusted to suit rider preference and deliver
excellent performance for a given set of conditions. However, all sus-
pension designs and adjustments 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 a snowcross course.
Refer to the suspension setup label on your snowmobile, or see your
Polaris dealer for initial suspension setup information. Additional
adjustments can be made after initial setup. Make adjustments to one
area at a time so you can evaluate the change. For further assistance, see
your dealer.
45
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THE PERFECT FIT
Rear Suspension Adjustments
Suspension Performance Tips
• Rider weight usually determines the position 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 setup. 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
worn rail slide. It can also improve top speed.
• When riding 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 flotation in deep snow. See
your dealer for assistance.
NOTE: Keep the suspension pivot points lubricated. This will reduce
moisture and rust build-up and ensure proper function of the
suspension components. Grease rear suspension pivots
before adjusting the rear suspension. Refer to Suspension
Maintenance beginning on page 120.
Track Tension
Track adjustment is critical for proper handling. Always maintain cor-
rect tension and alignment. Refer to the track tension maintenance sec-
tion beginning on page 114.
46
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Initial Spring Preload Setting (Sag Method)
To set up the IQ rear suspension tor-
sion spring preload, measure the
distance between the ground and
rear bumper. This is measurement
X.
Take the first measurement with no
rider and with the rear suspension at
full extension.
X
NOTE: The rear bumper may need
to be lifted upward slightly
to fully extend the rear sus-
pension.
Next, have the rider drop down hard
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 measure-
ment X. This is measurement Y.
Y
To determine sag, commonly referred to as ride-in, subtract measure-
ment Y from X (sag=X-Y). Adjust sag by rotating the torsion spring
preload cams located on the rear torque arm. See page 48.
NOTE: The ideal amount of sag recommended for the IQ rear suspen-
sion is 4-5 inches (10-13 cm).
47
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Torsion Spring Tension
To adjust rear torsion spring tension, rotate the three-position cam using
the engine spark plug tool. Adjustment is easiest when the cam is
rotated from low to medium, and then to high. Rotating directly from
low to high will require significantly more effort.
Different rate torsion springs are available if a firmer ride is desired.
See your dealer for more information.
A - Soft Tension
B - Medium Tension
C - Firm Tension
A
B
C
Rear Shocks
Polaris Position Sensitive Shock
There are no external adjustments on the Polaris position sensitive
(PPS) shock.
48
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Suspension Coupling
On all Polaris snowmobile rear suspensions, there are two torque arms
that control the movement of the rail beam. Prior to the advent of sus-
pension 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 rear suspension
coupling.
Front To Rear Coupling and the Front Rear Scissor Stop
(FRSS)
The front rear scissor stop (FRSS) couples the movement of the front
torque arm with the rear torque arm and limits the amount of indepen-
dence between the movement of the front torque arm and the rear torque
arm.
When hitting a bump, the front torque arm starts to compress. The
FRSS links that movement to the rear torque arm, causing it to compress
and raise the rear suspension up as one, allowing the suspension to hit
the bump only once and reducing kickback.
The factory setting is usually adequate for all riders and conditions.
49
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Rear To Front Coupling and the Rear Rear Scissor Stop
(RRSS)
The rear rear scissor stop (RRSS) couples the movement of the rear
torque arm with the front torque arm and limits the amount of indepen-
dent movement between the rear torque 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 performance. An adjustment dot is located on the
RRSS. This dot is on the longest end of the scissor stop.
Rear Rear Scissor Stop (RRSS) - Attributes
Moving the RRSS to a higher position will have the following effects on
the suspension:
• Reduced weight transfer.
• Improved chatter bump ride.
• Improved cornering performance.
50
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THE PERFECT FIT
IQ Rear Suspension Adjustments
Weight Transfer During Acceleration
The preferred method for controlling
weight transfer during acceleration is
by adjusting the rear rear scissor stop
(RRSS). The factory setting is the
best for most trail riding conditions.
HIGH
LOW
LOW
MEDIUM
To decrease weight transfer under
acceleration (for improved corner-
ing), rotate the RRSS to a higher
position with the scissor stop tool
located in your tool kit.
To increase weight transfer or ski lift
during acceleration, rotate the RRSS
to a lower position.
NOTE: Your dealer can help you
with initial setup and addi-
tional setup instructions to
help you achieve your opti-
mum ride.
51
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THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
The M-10 suspension has been designed to be very sensitive to rider
weight. Changes in rider weight of 25 lbs. (11 kg) or more might
require appropriate changes in settings. The following information has
been compiled to assist you in tuning your M-10 suspension to its maxi-
mum potential and achieve the best possible ride. Please take the time
to read and understand all the possible adjustments available with this
suspension.
Static Sag and Ride Height Settings
Static sag describes the difference in height of the rear bumper from the
suspension's fully extended position to its loaded height, with the rider
seated on the snowmobile. Too much sag will result in bottoming, and
too little sag will result in reduced rider comfort.
Sag is used to control ride quality and rebound travel. On this suspen-
sion, sag is controlled by two settings, the full range adjuster (FRA)
position and the rear spring preload.
1. To check sag, raise the rear bumper until the suspension is fully
extended (the rear shock will not extend any further). Measure the
distance from the ground to the bottom of the bumper (dimension
X) as shown in the illustration. Record the measurement.
2. Have the rider sit on the snowmobile and bounce up and down on
the seat a few times to set in the suspension. While the rider remains
seated, measure the distance from the ground to the top of the
bumper (dimension Y) and record it.
52
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THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
3. Subtract Y from X and you will have the SAG setting (X - Y = sag
setting. Example: 21 - 17 = 4).
NOTE: The ideal amount of sag recommended for the FAST M-10 rear
suspension is 3-4 inches (8-10 cm).
If the measured sag is incorrect, adjust the FRA position and rear spring
preload. See pages 54-55.
X
Y
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THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
FRA Position
The FRA setting is the primary rear suspension adjustment. It will have
the MOST effect on the rear suspension performance. To adjust the
FRA:
1. Refer to the initial set-up reference chart (located under the hood of
your snowmobile and on page 57) to determine the desired FRA
position.
2. To adjust, loosen the hex bolts (1) attaching the rear lower shock
cross shaft to the rail beam.
3. Using a 9/16I wrench, loosen the jam nuts (2) on the preload bolts.
4. Adjust the preload bolts (3) to the desired FRA position.
5. Tighten the jam nuts.
NOTE: Make sure the preload bolt contacts the slide block before tight-
ening the jam nut.
6. Tighten the hex bolts and torque to 35 ft. lbs. (47 Nm).
NOTE: When the M-10 suspension is new, it may take from 25 to 200
miles (40-300 km) to properly break in the springs and shocks,
at which time the suspension will be softer and may require
FRA re-adjustment.
2
3
1
54
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THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Static Sag and Ride Height Settings
Rear Spring Preload
If FRA position alone does not allow the setup of the proper amount of
sag, the center retainer of the rear track shock can be replaced with
optional retainers to adjust the preload and change the sag. See your
Polaris dealer for assistance.
OPTIONAL RETAINERS
Retainer Insert Retainer Part
Preload
Sag
Part Number
Number
5135077
5134923
5135080
Least
Middle
Most
Most
Middle
Least
5436109
NOTE: Whenever ordering any of the retainers listed in the chart,
always order the retainer insert as well. The insert is not
removeable once installed, so a new insert is needed when
installing a new retainer.
55
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THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Ski Pressure
Ski pressure is set at the factory to deliver the optimum balance between
ride and handling. If a rider prefers more ski pressure for improved
steering performance, adjustments can be made to the front limiter strap
and front arm mount.
1. Determine if the rider
prefers comfort or con-
trol. Lean toward the #4
setting for comfort and
toward the #3 setting for
aggressive riding.
4
3
2
1
2. For full hole adjust-
ments, remove the 5/16I
nut and flat washers from
the lower attachments of
the limiter straps and
2
3
4
relocate the straps to the
desired position (i.e.
move from position 4 to 3). Replace the nut and washer. Tighten
securely.
3. For half-hole increments (such as 3/4), the limiter straps have slots
at the upper pinch bolt. These slots allow the bolts to be loosened
(rather than removed) for half-step adjustments. Re-tighten the
pinch bolts.
56
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THE PERFECT FIT
FAST M-10 Rear Suspension Adjustments
Ski Pressure
4. There are also two front
arm mounting holes in
the slide rail that can
adjust ski pressure. The
lower hole (1) increases
ski pressure while the
upper hole (2) decreases
ski pressure.
2
1
NOTE: By design, the BIASED COUPLE design of the M-10 suspen-
sion displaces the rear arm as the front arm is compressed.
This means that when you raise the front limiter strap, at some
point you will collapse the rear suspension arm, which will
affect SAG height and reduce rear suspension travel.
Initial M-10 Suspension Set-up Chart
NOTE: The initial M-10 suspension set-up chart was not available at
the time of printing. Please see your Polaris dealer.
57
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THE PERFECT FIT
Handlebar Adjustments
Handlebar Position
Use the RIDER SELECT feature to adjust handlebar position. See page
27.
Handlebar Angle
Follow these steps to adjust
handlebar angle at the handle-
bar block.
1
1. Remove the handlebar
cover (1) to expose the
handlebar and the four
adjuster block bolts (2).
2
2. Using a 7/16I wrench,
loosen the four nuts (3) on
the bottom of the adjuster
block (turn handlebar to
left or right for access to
back nuts).
3
NOTE: If necessary, pry the
blocks apart with a
screwdriver.
3. Adjust the handlebar to the desired height. Be sure handlebars,
brake lever and throttle lever operate smoothly and do not hit the
fuel tank, windshield or any other part of the machine when turned
fully to the left or right.
4. Torque the handlebar adjuster block bolts to 11-13 ft. lbs. (15-18
Nm).
NOTE: Torque the front bolts first.
5. Reinstall the handlebar cover.
58
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THE PERFECT FIT
Accessories
Polaris offers a wide range of accessories for your snowmobile to help
make each ride more enjoyable.
Use only 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
• Injury to self or others
This applies, 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 Polaris parts. Please see your Polaris dealer for ser-
vice.
59
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THE PERFECT FIT
Traction Products
Studs
Before equipping your machine with traction products, be aware of the
laws in your area pertaining to the use of traction products.
Use only Polaris traction products on your snowmobile. Track warran-
ties are void if track damage or failure results from improper or exces-
sive stud installation or the use of non-Polaris traction products.
See your dealer about installing studs and/or carbides.
CAUTION
Always install wear strips before installing studs. Failure to install wear strips
may result in cooler or tunnel damage. See page 61.
Never add shims to the wear strip. Track damage will result because of lack
of clearance between upper carrier wheels and track.
Use of studs longer than the recommended length on machines equipped
with center coolers will result in center cooler damage or damage to the tun-
nel.
Track studding will enhance braking control on hard-packed snow or
ice, but extreme caution is still required on such surfaces. Steering abil-
ity may be reduced on hard-packed snow or ice.
When studded tracks are used, increased wear to the brake pads will
result from increased braking. Extended-wear brake pad kits are avail-
able. See your dealer.
CAUTION
Aggressive studding patterns may require grinding protruding stud bolts flush
to prevent idler wheel damage. Maintain track tension on studded tracks on
the tight side of the spec to prevent heat exchanger damage. The center of
the stud must be at least 1 1/8I (2.86 cm) from the outside edge of the track.
60
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THE PERFECT FIT
Traction Products
nCarbide Skags
A skag is a replaceable bar attached to the underside of the ski to assist
in turning the snowmobile and to prevent ski wear caused by contact
with roads and other bare terrain. Use carbide skags with studded tracks
to help maintain proper vehicle steering and control. See page 119.
If your machine has carbide skags, it may be necessary to add track
studs to maintain proper vehicle control. Maintain a proper balance
between the number of studs and the length of carbide on the skags (the
more studs you use, the longer the carbide on the skags should be). See
your dealer's track studding chart.
Wear Strips
To avoid excessive tunnel wear, tunnel wear strips must be installed
whenever track studding is used. Install Wear Strip Kit P/N 2874687.
Wear strips are designed for a specific stud length. See your dealer's
studding chart for recommended traction accessories.
CAUTION
Whenever wear strips are relocated, be sure there's adequate stud clearance
to the heat exchangers. Lack of clearance may result in damage to heat
exchangers.
61
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PRE-RIDE INSPECTIONS
Pre-Ride Checklist
Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the ref-
erenced pages. Look for a checkmark (n) on the referenced pages to
locate the pre-ride inspection items.
Item
See Page
Drive Belt Condition
Steering System
Recoil Rope
109, 111
66
67
Coolant Level
98
Park Brake Lock/Brake Lever/Brake System
Auxiliary Shut-Off Switch (Engine Stop Switch)
Ignition Switch
64, 65, 103
68
68
Taillight/Brakelight/Headlight
Suspension Mounting Bolts
Skags (Wear Bars)
68
120
119
120
67
Ski Saddle and Spindle Bolts
Hood Straps/Latches
Seat Latches (if equipped)
Throttle Lever/Safety Switch
Rear Wheel Idler Bolts
N/A
78, 79
115
68
Tether Switch/Strap
Track Alignment/Condition
Rail Slide Condition
66, 116
120
90
Chaincase Oil Level
Injection Oil Level
75
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PRE-RIDE INSPECTIONS
Before Starting the Engine
WARNING
Worn, damaged, or malfunctioning components may cause serious injury or
death. Before starting the engine, check all components to be sure of proper
operation.
Read and Understand Your Owner's Manual
Read the Owner's Manual completely and refer to it often. The manual
is your guide to safe and enjoyable snowmobiling experience.
n Throttle Lever
The throttle and brake are the primary controls of your snowmobile.
Always make sure both are functioning properly.
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.
n Throttle Safety Switch
Test the throttle safety switch system before the machine is operated.
See page 78.
63
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Brakes
Always check the following items for proper operation before starting
the engine.
Brake Lever Travel
Squeeze the brake lever. It
should move no closer to the
1/2I (1.3 cm)
handgrip than 1/2I (1.3 cm).
A smaller distance indicates
low brake fluid level or air in
the hydraulic system. Refer
to the brake bleeding infor-
mation on page 105 or see
your dealer for service.
Lever Feel
If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 104.
WARNING
Continued use of “spongy” brakes may cause a complete loss of brakes,
which could result in serious injury or death. Always have the brakes ser-
viced at the first sign of sponginess.
64
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Park Brake Lever Lock
Use the park brake lever lock only when you want the machine to
remain stationary; for example, when parked on an incline for a period
of five minutes or less.
1. Brake Lever
3
4
2
2. Park Brake Lever Lock
3. Master Cylinder Reser-
voir/ Cover
1
4. Fluid Level Indicator
Lock Engagement
To engage the lock, squeeze
the brake lever tightly and
push forward on the lock.
Hold the lock forward while
releasing the brake lever.
NOTE: If the brake lever is squeezed tightly enough, the lock will move
freely into place. Do not force the lock or it may break.
The brake light in the analog gauge will light up if the park brake lever
lock is set while the engine is running. It will also be lit when the ser-
vice brake is in use. If the park brake light does not come on when the
park brake or service brake is in use, have it serviced by your dealer.
Lock Release
To release the lock, squeeze the brake lever tightly. The lock will return
to the unlock position.
WARNING
If the park brake lever lock is partially or entirely engaged while riding, the
brakes may overheat, resulting in brake damage. In extreme cases it could
cause a fire, which could result in serious injury or death. Always ensure that
the lever lock is completely disengaged before operating the snowmobile.
65
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Steering System
WARNING
Ice and snow build-up may interfere with the steering of your machine, result-
ing in serious injury or death. Keep the underhood area free of snow and ice.
Before driving, manually turn the skis to the left and right to be sure ice
and snow are not interfering with full left and right steering. If difficulty
is encountered, remove ice and snow build-up that may be obstructing
the steering linkage.
NOTE: If your snowmobile is equipped with RIDER SELECT, perform
this check in both the full up and full down steering positions.
n Track
WARNING
Operating the snowmobile with a damaged track increases the possibility of
track failure, which 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 track dam-
age and/or failure. Driving at high speeds for extended periods of time in
marginal lubrication could severely damage track rods, break 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 caused by operation on ice or poor
lubrication conditions voids the track warranty.
66
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PRE-RIDE INSPECTIONS
Before Starting the Engine
n Hood Latches
The hood of the snowmobile protects the operator from moving parts as
well as aiding in sound emission control and other functions. Under no
circumstances 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 snowmo-
bile.
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 your Polaris dealer for replacement.
67
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PRE-RIDE INSPECTIONS
Start the Engine and Check
n Engine Stop Switch
Check the auxiliary shut-off switch for proper operation. Push the
switch down to stop the engine. 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 your machine has a tether switch, remove the tether from the switch to
make sure the engine stops immediately.
n Lighting
Check the headlight (high and low beam), taillight, and brake light.
Replace burned out lamps before operating.
n Mirror Adjustment (if equipped)
Adjust the mirrors so they can be used to their full advantage.
n Operating Area
Before driving away, check your surroundings. Be aware of obstacles
and make sure bystanders are a safe distance from the machine.
68
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OPERATION
Starting the Engine
WARNING
Before starting the engine, always refer to all safety warnings pertaining to
snowmobile operation. Never start your snowmobile without checking all
components to be sure of proper operation. See Before Starting the Engine
beginning on page 63.
Starting a Cold Engine (Manual Start)
Do not depress the throttle until
CHOKE TOGGLE POSITIONS
the engine starts.
1. Turn the fuel valve on. See
OFF
page 29.
2. Turn the key to the ON
position.
3. Pull the engine stop switch
HALF ON
up to the RUN position.
4. Flip the choke toggle to
FULL ON.
5. Grasp the recoil rope han-
dle and pull slowly until
the recoil engages; then
pull abruptly.
FULL ON
6. Repeat as needed until the engine starts.
WARNING
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 injury and/or engine damage, do not operate the electric starter or
pull-rope starter while the engine is running.
7. After the engine starts, flip the choke toggle to the OFF position. If
the engine slows or wants to stop, use intermittent choking to the
HALF ON position.
69
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OPERATION
Starting the Engine
Starting a Warm Engine
1. Turn the key to the ON position.
2. Pull the engine stop switch up to the RUN position.
3. Grasp the recoil rope handle and pull slowly until the recoil
engages; then pull abruptly.
If the engine does not start on the first pull, slightly depress the throttle
with your left hand (no more than 1/4I open), and pull the rope with
your right hand. When the engine starts, immediately release the throt-
tle.
Engine Break-In
No single action on your part is as important to long, trouble-free
machine life as proper break-in of a new or rebuilt engine. Premix the
first tank of fuel with one pint of Polaris injection oil for each five gal-
lons of fuel. This, in addition to the lubrication supplied by the injection
system, will assure proper engine break-in.
CAUTION
Excessive heat build-up during the first 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 open-
ings 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 engine damage. We recommend the use of Polaris lubricants for
your vehicle.
Drive with extra caution during the break-in period. Perform regular checks
on fluid levels, lines, and all other important areas of the machine.
70
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OPERATION
Engine Break-In
Oil Injection System
Always check and fill the oil tank when refueling. See page 75.
CAUTION
Serious engine damage can occur without the proper lubrication. Check the
oil tank level often during the first tank of fuel. If the oil level doesn't go down,
contact your dealer immediately.
Oil Recommendations
This snowmobile is equipped with a variable exhaust system (VES).
Engine lubrication comes from oil added to the fuel and oil injection
systems. Polaris recommends the use of VES II 2 Cycle Oil for this
engine. See page 124 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
CAUTION
Inadequate cooling and lubrication will lead to overheating of the slide rail
and track, resulting in premature wear and failure. Reduce speeds and fre-
quently drive into fresh snow to allow adequate cooling and polishing of the
slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or
roads.
71
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OPERATION
Track Warm-Up
WARNING
A loose track or flying debris could cause serious injury or death. Stand clear
of the front of the machine and the moving track. Never hold the snowmobile
up or stand behind it while warming up the track. Do not use excessive throt-
tle during warm-up or when the track is free-hanging. Use a stable rear sup-
port.
WARNING
Use of traction products such as studs, ice growsers, etc. will increase the
possibility of track damage and/or failure. This could cause loss of control,
resulting in serious injury 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-
port the rear of the snowmobile at the rear
bumper. The track should be about 4I (10
cm) off the ground.
2. Start the engine and allow it to warm up
two to three minutes.
3. Depress the throttle abruptly and allow the
track to rotate several revolutions.
NOTE: It will take longer to warm up the track
sufficiently during colder outdoor tem-
peratures.
4. Release the throttle, apply the brakes, shut off the engine and lower
the machine to the ground.
5. Grasp the skis by their front loops and move them from side to side
to loosen snow and ice.
72
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OPERATION
Fuel
WARNING
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel outdoors or in a well-ventilated area.
• Always turn off the engine before refueling.
• 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 water and change clothing.
• Never start the engine or let it run in an enclosed area. Engine exhaust
fumes are poisonous and can cause loss of consciousness or death in a
short time.
• Turn the fuel valve off whenever the snowmobile is stored or parked.
WARNING
The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.
73
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OPERATION
Fuel
For peak performance, Polaris recommends the use of 91 octane or
higher fuel. Although 87 octane fuel is usable, some engine perfor-
mance will be lost and fuel economy will decrease. Do not use fuel
lower than 87 octane.
CAUTION
Operating with obstructed fuel systems will result in serious engine damage.
Perform maintenance as recommended.
Prolonged exposure to petroleum based products may damage paint.
Always protect painted surfaces when handling fuel.
Fuel Level
The fuel symbol and the last fuel bar on the MFD gauge will blink when
the fuel level reaches 1/8th tank. There will be one to two gallons of fuel
remaining. Refuel as soon as possible.
NOTE: Restarting the engine will be more difficult if the snowmobile
runs out of fuel. Do not allow the snowmobile to run out of fuel.
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 gasoline to prevent engine damage resulting from
fuel system icing and lean fuel mixtures. Never use deicers or additives
containing methanol. Polaris also recommends the use of Carbon Clean
Plus. See page 124 for the part numbers of Polaris products.
If you use oxygenated fuel containing ethanol, additional alcohol deic-
ers or water absorbing additives should not be used.
74
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OPERATION
Oil
n Low Oil Indicator Light
The low oil indicator light will alert the operator if the oil level is low.
Visually check for oil in the bottle. Add oil before further operation of
the snowmobile. See page 71 for oil recommendations.
n Low Oil Level
Maintaining the proper oil level will prevent system aeration and possi-
ble loss of pumping action, which could result in engine damage. This is
especially important when the machine is operated in mountainous ter-
rain.
CAUTION
Operating the snowmobile without adequate engine lubrication can result in
serious engine damage. Always check the oil level when refueling. Add oil
as needed.
Always maintain a visible level of oil in the tank. If oil is not visible,
continued operation may cause serious engine damage. See page 71 for
oil recommendations.
The Polaris oil cap on the oil bottle is vented to allow proper oil flow.
See your Polaris dealer for recommended replacement parts.
75
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OPERATION
Carburetion
Proper carburetor adjustment is critical. A lean mixture (too much air,
too little 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.
Either condition may be caused by improper carburetor adjustment.
WARNING
Improper carburetor adjustments may result in operator safety hazards as
well as serious engine damage. Always have your Polaris dealer perform
any carburetor adjustments.
76
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OPERATION
Carburetion
Jetting Guidelines
Changes in altitude and temperature affect air density, which is the
amount of oxygen available for combustion. In low elevations and cold
temperatures, the air has more oxygen. In higher elevations and higher
temperatures, the air is less dense.
The carburetors are calibrated for an altitude of 0-2000 ft. (0-600 m) and
ambient temperatures between -10_ to +10_ F. (-23_ to -12_ C). Carbu-
retors must be re-calibrated if the snowmobile is operated outside this
production temperature and/or altitude range. The main jet installed in
production is not correct for all altitudes and/or temperatures. See page
96 for more information.
CAUTION
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 in your Owner's Manual Supple-
ment.
NOTE: It's the owner's responsibility to ensure that the correct jets are
installed in the machine for a geographical area. Be very care-
ful when jetting down in warm weather. As the weather turns
colder it will be necessary to re-jet upward to prevent engine
damage. When selecting the proper main jet always use the
lowest elevation and temperature that is likely to be encoun-
tered.
77
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OPERATION
n Engine Stop Switch
Push down on the engine
stop switch (✪) to
ground out the ignition
and stop the engine
✪
quickly. Pull the switch
up to the ON position to
allow restarting.
n Throttle Safety Switch
The throttle safety switch is designed to stop the engine whenever all
pressure is removed from the throttle lever and the throttle cable or
valves do not return to the normal closed position.
WARNING
Operating the snowmobile with a faulty throttle safety switch can result in
serious injury or death in the event of an accident. If the throttle safety switch
does not shut off the engine during a carburetor/throttle system malfunction,
immediately push down the engine stop switch. Do not start the engine
again until the malfunction has been corrected by your dealer.
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 pressure 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.
78
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OPERATION
Throttle Lever
WARNING
An improperly functioning throttle lever may cause erratic machine behavior
and loss of control, which could result in serious injury or death. If the throttle
lever does not work properly, DO NOT start the engine.
If the engine stops abruptly when the throttle lever is released:
1. Turn the ignition switch to OFF.
2. Visually inspect the throttle cable and carburetor to determine what
caused the safety switch to activate.
3. Test the throttle lever by compressing and releasing it several times.
The lever and cable must return to the idle position quickly and
completely.
4. If the throttle lever operates properly, turn the ignition switch on and
go through normal starting procedures.
5. If the engine doesn't start, take the snowmobile to an authorized
Polaris dealer for service.
Excessive freeplay 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 used to shut off the engine. DO NOT continue to operate the
machine with the throttle safety switch disconnected. Return the
machine to an authorized Polaris dealer for service as soon as possible.
79
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OPERATION
Emergency Stopping
The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 78 for more information about the
engine stop switch and throttle safety switch.
THROTTLE
CONDITION
SYSTEM
Ignition Switch
WHAT IT DOES
Interrupts ignition circuit
Slows jackshaft
All
Brake
All
Choke
Floods engine
Half throttle or less
Engine Stop Switch
Throttle Safety Switch
Tether Switch (Option)
Interrupts ignition circuit
Interrupts ignition circuit
Interrupts ignition circuit
All
All
All
80
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OPERATION
Emergency Starting
If the recoil starter system fails, an emergency start strap is provided in
the tool kit.
1. Open the hood.
2. Remove the left side panel.
3. Using the belt removal tool,
follow the directions on the
air box to relieve belt tension.
4. Starting at one of the tower
struts, wind the strap counter-
clockwise around the clutch
as shown.
WARNING
Serious injury can result from wrapping the start strap around your hand
while using the emergency starting procedure. DO NOT wrap the start strap
around your hand. Keep all bystanders and loose clothing away from the
snowmobile when using the emergency starting procedure.
5. Pull the strap abruptly so the strap comes free of the clutch while
starting the engine. Repeat until the engine starts.
6. Reinstall the side panel.
7. Close and secure the hood.
81
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OPERATION
Electronic Reverse (PERCt)
Electronic reverse will activate only if the engine RPM is below 4000.
WARNING
Improper reverse operation, even at low speeds, may cause loss of control,
resulting in serious injury or death. Damage will occur to the chaincase or
transmission if shifting is attempted when the engine is operating above idle
speed.
• Shift to or from reverse only when the snowmobile is stopped and when
engine speed is at idle.
• Look behind the vehicle before and while backing.
• Avoid sharp turns.
• Apply throttle slowly.
Engaging Reverse
1. Stop the snowmobile and leave the engine idling.
2. Make sure the area behind your vehicle is clear.
3. Push the yellow reverse button on the left-hand control for one sec-
ond, then release. The engine will automatically reduce RPM and
start a reverse rotation. A flashing reverse light on the instrument
panel will indicate that the machine is in reverse.
4. Apply the throttle slowly to make sure the machine is in reverse.
NOTE: The maximum engine RPM will be 6000 when in reverse.
NOTE: If the engine stops running, the snowmobile will be in forward
gear when it's restarted.
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 on the
instrument panel will shut off.
3. Apply the throttle slowly to make sure the machine is in forward.
82
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OPERATION
Daily Storage
At the end of each ride, park the snowmo-
bile on a level surface and support it at the
rear with an appropriate track stand. The
track should be suspended approximately
4I (10 cm) off the ground.
Remove the key and cover the machine.
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, or any type of vehicle with a
rope. Only a stiff metal pole connecting the towed object and the tow hitch
on the snowmobile should be 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 per-
son riding in the towed object.
Braking distances increase when towing loads. Slow down to maintain con-
trol of the snowmobile.
If the snowmobile becomes inoperable and must be towed, and if it isn't
possible to use a rigid tow bar, attach the tow rope to the ski spindles
(not to the ski loops) to prevent damage to the steering components.
Remove the drive belt before towing, and have someone ride on the
towed snowmobile to operate the brake and steering when necessary.
CAUTION
Towing a disabled snowmobile with the drive belt in place can result in seri-
ous damage to the engine and drive system. Always remove the drive belt
from a disabled snowmobile before towing.
83
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MAINTENANCE
Polaris Recommended Maintenance Program
To ensure many trouble-free miles of snowmobiling enjoyment, follow
recommended regular maintenance and perform service checks as out-
lined in this manual. Record maintenance and service in the Mainte-
nance Log beginning on page 138.
The recommended maintenance schedule on your snowmobile calls for
service and maintenance inspections at 150 miles (240 km), 500 miles
(800 km) and 1000 miles (1600 km). These inspections should be per-
formed by a qualified service technician. For continued optimum per-
formance and component life, 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 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 to service or make adjust-
ments to your snowmobile. If you're not familiar with safe service or
adjustment procedures and the use of tools, or if you don't feel comfort-
able performing these tasks yourself, contact an authorized Polaris
dealer for service.
CAUTION
Hot components can cause damage to plastic. Always make sure the
exhaust system and engine have cooled before tipping the snowmobile on its
side for service or inspection.
84
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MAINTENANCE
Periodic Maintenance Interval Table
The following chart is a guide based on average riding conditions. You
may need to increase frequency based on riding conditions. When
inspection reveals the need for replacement parts, always use genuine
Polaris parts, available from your Polaris dealer.
Item
See
Page
Frequency
1000 mi.
150 mi.
500 mi.
2000 mi.
Pre-
Season
(240 km) (800 km) (1600 km) (3200 km)
CLUTCH
Clutch Alignment Offset
(without belt)
108
I
I
I
Drive Belt Condition
Clutches (disassemble)
Belt Tension
109
108
--
I
I
C
I
I
C
I
I
C
I
I
I
Clutch Sheaves
108
I
I
I
ENGINE/COOLING
Engine Mounts
--
--
I
I
I
I
I
I
I
I
I
I
I
Recoil Rope
Engine Torque Stop
Cylinder Head Bolts
Cylinder Base Nuts
Ignition Timing BTDC
VES System
111
--
I
I
I
I
--
I
I
I
I
I
--
I
I
--
C
I
C
I
C
R
I
I
I
I
I
Coolant Level
98
--
Coolant Hose
I
I
Heat Exchangers
Coolant Circulation
Coolant Leaks
100
--
I
I
I
I
I
I
I
I
--
I
I
I
I
I
I
I
Spark Plug Condition
Exhaust Pipe
93
101
101
I
I
R
I
Exhaust Retaining
Springs
I
I
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate
85
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MAINTENANCE
Periodic Maintenance Interval Table
Item
See
Page
Frequency
1000 mi.
150 mi.
500 mi.
2000 mi.
Pre-
Season
(240 km) (800 km) (1600 km) (3200 km)
BRAKES
Hose Routing
Hose Condition
Fluid Leaks
--
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
--
Brake Pads
103
--
Brake Disc
Parking Brakes
Brake System
65
64,
103
Brake Fluid
104
R
FUEL MANAGEMENT
Pilot Air Screws
--
I
I
I
I
I
I
Carburetor
96
(synchronize)
Idle RPM
--
79
--
I
I
I
I
I
I
I
Throttle Lever
I
I
I
I
Oil Pump Lever
(synchronize)
Throttle Cable
Choke Cable
Choke
89
89
89
--
L
L
I
L
L
I
L
L
I
Vent Lines
I
I
I
I
I
Throttle Position
Sensor
--
I
I
I
Fuel Lines
Fuel Filter
95
95
94
94
--
I
I
I
I
R
R
I
I
R
R
I
Oil Filter
Oil Lines
I
I
Air Box
I
I
I
I
Drain and Water Traps
97
I
I
ELECTRICAL
Auxiliary Shut-Off
Switch
68
I
I
I
I
I
Throttle Safety Switch
Ignition Switch
Taillight
78
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
68
68
68
Brakelight
Headlight
86
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MAINTENANCE
Periodic Maintenance Interval Table
Item
See
Page
Frequency
1000 mi.
150 mi.
500 mi.
2000 mi.
Pre-
Season
(240 km) (800 km) (1600 km) (3200 km)
CHASSIS
Ski Toe Alignment
--
--
I
I
I
I
I
I
Suspension Mounting
Bolts
I
I
Steering Fasteners
--
--
I
I
I
I
I
I
I
I
C
I
Rear Suspension Fas-
teners
Suspension Shock Oil
--
--
I
I
I
I
I
I
I
I
Cooling Fins and
Shroud
Drive Shaft Bearing
Jackshaft Bearings
Skags (Wear Bars)
89
122
119
--
L
L
I
L
L
I
L
L
I
I
I
I
I
I
I
Ski Saddle/Spindle
Bolts
I
I
I
Drive Chain Tension
Hood Latches
102
67
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Rear Wheel Idler Bolts
Idler Bolt Jam Nut
115
115
88
I
I
I
I
I
I
Rear Suspension Pivot
Shafts
L
L
L
Camber Alignment
Handlebar Centering
Tether Switch and Strap
Track Alignment
--
--
I
I
I
I
I
I
I
I
I
I
68
116
114
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Track Tension
Front Limiter Strap
Rail Slide Condition
Chaincase Oil
120
90
I
I
I
R
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate
87
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MAINTENANCE
Lubrication
Front Suspension
The front suspension and steering components do not require lubrica-
tion.
Rear Suspension
Lubricate the suspension 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 affect your ride and the life of the suspension. For more infor-
mation about suspension lubrication and adjustments, see your Polaris
dealer.
IQ Rear Suspension
✪
✪
✪
✪
M-10 Rear Suspension
✪
✪
✪
✪
88
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MAINTENANCE
Lubrication
Driveshaft Bearing
✪
Inject grease into the fitting on the
speedometer sensor housing until
grease purges from the seal on the
inside of the tunnel. This should
take approximately two pumps.
Do not use more 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
✪
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 reduce the possibility of the
choke becoming frozen.
89
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MAINTENANCE
Lubrication
n Chaincase Oil
Check the chaincase oil level at the
intervals outlined in the maintenance
charts beginning on page 84. The sight
glass (1) is located on the lower rear of
the chaincase. Maintain the oil level at
or slightly below the center of the sight
glass (2). Change the chaincase oil after
the first 500 miles (800 km), then every
1000 miles (1600 km) or seasonally.
3
Polaris recommends the use of Polaris
Synthetic Chaincase Lube. See page
124 for the part numbers of Polaris prod-
ucts.
1
Oil Check
1. Position the vehicle on a level sur-
face.
2. View the oil level at the sight glass.
2
3. Remove the fill plug (3) and add the
recommended oil as needed. Do not
overfill.
4. Reinstall the fill plug, making sure it
is seated properly.
90
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MAINTENANCE
Lubrication
Chaincase Oil
Oil Change
1. Position the vehicle on a level surface.
2. Remove the drain plug (4) and drain
the oil into a drain pan. Allow the oil
to drain completely.
4
3. Install a new sealing washer on the
drain plug.
NOTE: The sealing surfaces on the drain plug and the oil tank should
be clean and free of burrs, nicks or scratches.
4. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).
5. Remove the fill plug.
6. Add 11 oz. (325 ml) of the recommended oil. Do not overfill.
7. Reinstall the fill plug, making sure it is seated properly.
91
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MAINTENANCE
General Maintenance
Spark Plugs
A new engine can cause temporary spark plug fouling due to the preser-
vative added during the assembly process. Avoid prolonged idle speeds,
which cause plug fouling and carbonization.
Refer to your Owner's Manual Supplement for the specific spark plug to
be used in your machine.
Change the spark plugs every 2000-2500 miles (3200-4000 km).
CAUTION
Using non-recommended spark plugs can result in serious engine damage.
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. See your
Owner’s Manual Supplement.
• Use recommended spark plugs with the proper gap.
• Use only resistor-type spark plugs.
• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).
• Always carry spare spark plugs.
92
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MAINTENANCE
General Maintenance
Spark Plug Condition
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed up
and the vehicle has been driven at higher speeds. Immediately check the
spark plug for correct color.
WARNING
A hot exhaust system and engine can cause serious burns. Wear protective
gloves when removing a spark plug for inspection.
NOTE: Incorrect fuel mixture can 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 carbure-
tor(s). Refer to the Owner's Manual Supplement or see your
dealer.
1. Normal
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.
NOTE: The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incor-
rect carburetor/throttle body adjustments.
2. Wet Fouled
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
of non-recommended injection oil, improper use of the choke, or incor-
rect carburetion adjustments.
93
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MAINTENANCE
General Maintenance
Spark Plug Removal and Replacement
1. Remove the spark plug cap.
2. Using the special wrench provided in
the tool pouch, rotate the spark plug
counterclockwise to remove.
3. Reverse the procedure for spark plug
installation.
4. Torque to 18-22 ft. lbs. (24-30 Nm).
5. Reinstall the spark plug cap.
Oil Lines
Inspect oil line condition every 1000 miles (1600 km).
Oil Filter
The oil filter is located at the side of
the oil tank. Have your dealer change
the oil filter and bleed the system
annually or every 1000 miles (1600
km).
NOTE: The direction of the arrows
indicates the direction of
flow through the filter.
94
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MAINTENANCE
General Maintenance
Intake Filters
The intake foam filters (✪)
limit snow ingestion into
the intake system. When
operating in loose powder
snow, check the foam filters
periodically to remove any
accumulation of snow.
✪
CAUTION
Operating the snowmobile with the intake filters removed may cause carbu-
retor icing. The result will be poor fuel economy or carburetor malfunction.
Always reinstall the intake filters before operating the snowmobile.
Fuel Pump
All fuel pump service must be performed by an authorized Polaris
dealer. Do not attempt to service the fuel pump.
Fuel Filter/Fuel Lines
See your Polaris dealer for replacement of the in-tank fuel filter every
1000 miles (or annually).
Inspect the fuel lines regularly for signs of deterioration or damage.
Always check fuel line condition after periods of storage. Normal dete-
rioration from weather and fuel compounds may occur. Replace worn
or damaged fuel lines promptly.
CAUTION
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.
95
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MAINTENANCE
General Maintenance
Carburetor
The number stamped in the end of the main jet indicates the jet size.
The jet installed at the time of manufacture is not necessarily correct for
your elevation. It's your dealer's responsibility to make sure the correct
main jet is installed.
CAUTION
Operating the snowmobile with incorrect jetting can result in serious 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 need
adjustment:
• Hard starting
• Poor idle
• Overheated pistons and cylinder walls
• Plug fouling
• Poor engine response to various throttle valve openings
96
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MAINTENANCE
General Maintenance
Carburetor Water/Sediment Trap
Most Polaris snowmobiles contain patented carburetor bowl water/sedi-
ment traps located at the bottom of each carburetor. The trap, consisting
of a hose with a plug, should be drained about every 1000 miles (1600
km) and inspected for contamination.
WARNING
When draining the traps, fuel spillage will occur. Always work in a well venti-
lated area away from anything that may cause the fuel to ignite, such as open
flames, sparks, heaters, trouble lights, cigarettes, etc. Review the fuel warn-
ings on page 73.
Cleaning Procedure
1. Turn the fuel valve off.
2. Place a container or shop
towels below the plug to
catch drained fuel.
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 plug
and reinstall it. Reposition
and tighten the clamp.
1
2
5. Repeat the draining proce-
dure for any remaining traps.
97
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MAINTENANCE
General Maintenance
Coolant
The coolant supplied in the system is a 60/40 mixture of ethylene-glycol
and distilled water. This mixture provides protection against freezing.
Contact your dealer if greater protection is required.
Use Premium 60/40 anti-freeze coolant, which is already premixed and
ready to use. Do not dilute with water. Never exceed a 60% antifreeze/
40% water mixture. See page 124 for Polaris products.
NOTE: Never add tap water to the cooling system. Minerals cause
deposits and may react adversely with the metals in the engine
and cooling system.
n Coolant Level
The engine coolant level is controlled by the recovery system. The
recovery system components are:
• Coolant bottle or overflow tank
• Engine filler neck
• Pressure cap
• Connecting hoses
Always maintain the coolant level between the minimum and maximum
marks on the coolant bottle (when engine is cold) to prevent overheating
and serious engine damage.
CAUTION
Operating the snowmobile with insufficient coolant will result in overheating
and serious engine damage. Always maintain the coolant level as recom-
mended.
98
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MAINTENANCE
General Maintenance
Coolant High Temperature Indicator Light
WARNING
Steam and hot liquids will cause serious burns to your skin. Never remove
the pressure cap when the engine is warm or hot.
The high temperature indicator light will illuminate when engine cool-
ant temperature becomes too hot for safe continued operation of the
engine. If you must drive your machine after the high temperature indi-
cator light has come on, drive slowly and stop frequently to allow the
engine to cool down. Driving in deep snow will also help cool the
engine. See your dealer for service. Add coolant if the level is low.
NOTE: Engine performance will be reduced if you continue operating
when the high temperature light is on.
Flushing the Cooling System
To ensure that the coolant maintains its ability to protect the engine,
drain the system completely every two years and add a fresh mixture of
antifreeze and distilled water. This service must be performed when the
engine is cold. Ask your Polaris dealer to check the coolant when he
performs the fall tune-up on your snowmobile.
99
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MAINTENANCE
General Maintenance
Bleeding the Cooling System
WARNING
Steam and hot liquids will cause serious burns to your skin. Never bleed the
cooling system or remove the pressure cap when the engine is warm or hot.
Use of a non-standard pressure cap will not allow the recovery system to
function properly. If the pressure cap needs replacement, contact your
dealer for the correct part.
CAUTION
If coolant flow becomes restricted or plugged, coolant loss, air lock or engine
damage may result. Most cooling systems are equipped with a filter that
should be periodically inspected or replaced.
Perform the bleeding procedure when the engine is cold.
1. Remove the pressure cap and fill the coolant bottle with properly
mixed coolant to the maximum mark.
2. Elevate the front end of the machine slightly to aid in bleeding of
the heat exchangers.
3. Remove the bleed screw from the water outlet manifold and/or the
thermostat housing. Allow the coolant to bleed through the system
until it runs out the bleed holes. Reinstall the bleed screw into the
manifold.
4. Add coolant to the coolant bottle to the maximum mark.
5. Start the engine and run at a fast idle for two to three minutes.
Loosen the bleed screw occasionally to purge any trapped air.
6. Stop the engine and check the coolant bottle level. Fill as required.
7. Feel the heat exchangers under the running boards. If the system is
bled properly, they'll be warm to the touch. If they're not, repeat
step 5. Lift the front of the machine slightly to assist in the bleed-
ing.
8. Replace the pressure cap and carefully lower the front end of the
machine.
100
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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.
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
running.
101
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MAINTENANCE
General Maintenance
Drive Chain Tension
Check drive chain tension weekly and
before each long trip. To obtain correct
chain tension:
1. Rotate the driven clutch counter-
clockwise to move all chain slack to
the tensioner side. Lock the brake
lever lock, or have an assistant hold
the brake lever firmly.
2
2. Loosen the adjuster bolt jam nut (1).
1
3. Finger tighten the adjuster bolt (2)
until it can no longer be adjusted by
hand, then back off 1/4 turn.
4. Tighten the jam nut while holding
the adjuster bolt. Torque to 21 ft.
lbs. (28 Nm).
5. Release the brake lever lock.
102
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MAINTENANCE
General Maintenance
n Hydraulic Brake Inspection
Inspect the brake lever reserve before each use of the snowmobile. See
page 64.
Brake pads must be replaced when the brake pad material becomes thin-
ner than the backing plate (approximately 1/16I). A kit is available for
replacing brake pads. See your dealer.
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 pads when the brake pad material becomes thinner
than the backing plate (approximately 1/16I).
Brake Components
1. Brake Caliper
3
1
2. Brake Disc
3. Brake Pad Material
(Replace when thickness is
less than 1/16I/1.5 mm).
2
Excessive Lever Travel
Hydraulic brakes are self-
adjusting, but if excessive
brake pad clearance develops,
bring the machine to an autho-
rized Polaris dealer for inspec-
tion and adjustment.
103
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MAINTENANCE
General Maintenance
Brake Fluid
The brake fluid level can be seen through 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.
Replace brake fluid at least every two years with Polaris DOT 4 high
temperature brake fluid. See page 124 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 serious injury.
WARNING
Keep the master cylinder cover free of dirt and debris. The vent slits allow for
diaphragm movement, and if they become plugged, movement of brake fluid
below the diaphragm may be restricted, altering brake function.
CAUTION
Brake fluid will damage decals, paint and some plastics. Always wipe up
spills immediately.
104
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MAINTENANCE
General Maintenance
Bleeding the Hydraulic Brake System
Air in the hydraulic brake system will cause spongy brake lever action.
Bleed the system before operating the snowmobile.
WARNING
Operating the vehicle with a spongy brake lever can result in loss of brakes,
which could cause an accident and lead to serious injury or death. Never
operate the vehicle with a spongy-feeling brake lever.
During the bleeding procedure, keep the brake handle as level as possi-
ble. The reservoir must be in this position to minimize the possibility of
air entering the system through the reservoir vent.
1. Remove the brake master cylinder reservoir cover and gasket.
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 the 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.
WARNING
Overfilling the master cylinder leaves no room for fluid expansion and may
cause the brakes to lock, resulting in serious injury or death. Always add
brake fluid to the fill line as recommended.
7. After bleeding is complete, refill the reservoir to the proper level.
See page 104.
8. Reinstall the gasket and cover.
105
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MAINTENANCE
General Maintenance
NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin
leaves a residue, causing a hot spot that will shorten the life of
the lamp. If fingers do touch the bulb, clean it with an alcohol-
moistened towel.
Headlight Bulb Removal
1. Remove the plenum covering
from the headlight assembly.
2. Lift the rubber boot to expose
the bulb.
2
3. Push down on the spring (1)
to release it from the housing.
3
4. With the wire harness (2)
attached to the bulb (3), with-
draw the bulb from the hous-
ing.
1
5. Grasp the bulb by its metal base and carefully separate the bulb
from the harness.
Headlight Bulb Installation
1. Hold the bulb by its metal base and install it into the wire harness.
2. Insert the bulb into the housing.
3. Connect the spring to the housing.
4. Carefully flip the spring back into the housing, placing it around the
wire harness.
5. Reinstall the plenum covering on the headlight assembly.
6. Verify headlight aim.
106
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MAINTENANCE
General Maintenance
Taillight/Brakelight Replacement
1. Open the rear storage compart-
ment.
2. Reach into the compartment and
locate the socket assembly above
the door opening.
3. Turn the socket counterclockwise
1/4 turn.
4. Carefully pull the socket assembly
away from the taillight.
5. Replace the bulb and reinstall the socket assembly.
6. Secure the storage compartment door.
107
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MAINTENANCE
General Maintenance
Clutch System
Periodically inspect clutch sheaves for damage, wear or belt residue. To
maintain optimum performance, clean with non-oil based cleaners such
as isopropyl alcohol.
WARNING
If you become aware of higher than normal clutch engagement or an unusual
vibration or shift pattern, see your dealer immediately. Do not operate the
machine until repairs have been made.
All clutch maintenance and repairs must be performed by an authorized
Polaris dealer. Any unauthorized modifications to clutches, such as adding
or removing weights, will void the warranty.
CAUTION
The bushings in the weights and rollers of Polaris clutches are made of a
material that may be damaged if lubricated. Do not lubricate clutch bushings.
Clutch Alignment Offset
Clutch alignment offset is important for maintaining optimum perfor-
mance. See your dealer for service and adjustments. A special tool is
required to check for proper alignment.
Clutch Center Distance
See your Owner's Manual Supplement for recommended center distance
for your machine. If adjustment is necessary, see your dealer.
108
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MAINTENANCE
General Maintenance
n 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
130.
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
CAUTION
Do not attempt to remove the drive belt after operating in reverse. The snow-
mobile must be stopped after forward motion to prevent damage to compo-
nents during belt removal.
1. Stop the engine after operat-
ing 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.
109
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MAINTENANCE
General Maintenance
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 rotation by
positioning the identifica-
tion numbers so that you
can read them. If
required, separate the
sheaves as outlined in
the belt removal proce-
dures.
2. Rotate the L-wrench counter-clockwise to tighten the sheaves while
working the belt to the outer edge of the sheaves.
3. Remove the wrench and store it in the tool kit.
4. Reinstall the side panel.
5. Close and secure the hood.
Drive Belt
Belt width and length must match the center distance of the clutches and
sheave width of the drive clutch. Polaris recommends the use of O.E.M.
belts. Other belts may match the dimensions, but can drastically change
the shift pattern, resulting in poor performance.
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.
110
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MAINTENANCE
General Maintenance
n Drive Belt Deflection
1
Measure belt deflection with
both clutches at rest and in
their full neutral position.
2
Place a straight edge (1) on the
belt and apply downward pres-
sure while measuring at point
2. This measurement should be
1 1/4I (3.2 cm).
Drive Belt Adjustment
TEAM Clutch
1. Loosen the 7/16I jam nut on the belt width adjuster.
2. Using a 1/8I 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 distance.
3. Tighten the jam nut.
Torque Stop
Periodically check torque stop clearance. With clutches in proper align-
ment, the clearance should be .010I-.030I (.25-.75mm) from the engine
case. Adjust if necessary. Lock the jam nut.
.010-.030I
(.25-.75 mm)
111
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MAINTENANCE
General Maintenance
Tool Kit
A tool kit is included with each machine for emergency and routine
maintenance. Always keep the tool kit with the snowmobile.
Fall Tune-Up
For maximum performance, arrange for a fall service tune-up with your
Polaris dealer. His experienced and trained service technician will keep
your machine in peak operating condition.
112
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MAINTENANCE
Track Maintenance
Track Inspection
WARNING
Broken track rods can cause a rotating track to come off the machine, which
could cause serious injury or death. Never operate with a damaged track.
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
check for damage.
3. Carefully examine the track
along the entire length of each
rod (✪). Bend the track to
check for breakage.
4. Replace the track if any rod
damage is found.
✪
Track Lubrication
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 serious injury or death. Avoid operating for extended peri-
ods on ice and other 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 limited lubrication, resulting in excessive wear.
NOTE: If excessive rail slide wear occurs due to poor snow conditions,
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.
113
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MAINTENANCE
Track Maintenance
WARNING
Moving parts can cut and crush body parts. When performing the checks
and adjustments recommended on the following pages, stay clear of all mov-
ing parts. Never perform track measurement or adjustments with the engine
running.
Track Tension
Track adjustment is critical for proper handling. Always maintain cor-
rect tension and alignment.
TRACK TENSION DATA CHART
Measurement
Location
Slack
Measurement
Suspension
IQ
Weight
10 lbs. (4.54 kg)
16I ahead of
rear idler shaft
3/8I-1/2I
(1-1.3 cm)
M-10
10 lbs. (4.54 kg)
16I ahead of
rear idler shaft
7/8I-1 1/8I
(2.2-2.9 cm)
NOTE: 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. Place the recommended weight or downward pressure on the track
at the specified distance (see chart) ahead of the center of the rear
idler wheel.
NOTE: Measure at the point where the weight is hanging.
114
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MAINTENANCE
Track Maintenance
Track Tension
4. Check for specified slack between the wear surface of the track clip
and the plastic slider. Refer to the Track Tension Data Chart on page
114.
If the track needs adjustment:
5. Loosen the rear idler shaft bolt.
6. Loosen the locknuts.
Adjusting Screw
Slack Measurement
Lock Nut
Shaft Bolt
S
Track
16I(40 cm)
10 lbs. (4.54 kg)
7. Tighten or loosen the track adjusting screws (4) to provide equal
adjustment on both sides of the track.
8. Repeat the measurement on the other side of the track.
NOTE: Check more frequently when the machine is new.
9. Start the machine and slowly rotate the track at least five revolu-
tions. Let the track come to a stop (do not apply brakes).
10. Check track alignment (see page 116) and adjust as necessary.
11. Tighten the locknuts.
12. Tighten the idler shaft bolts.
13. (n) Torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).
115
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MAINTENANCE
Track Maintenance
n Track Alignment
Periodically check that the track is centered and running evenly on the
slide rails. 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 the track
turns slowly at least 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
idler shaft bolts, then
loosen the left locknut and
tighten the left adjusting
bolt. If the track runs to
the right, loosen the idler
shaft bolts, then loosen the
right locknut and tighten
the right adjusting bolt.
4. After adjustments are com-
plete, tighten the locknuts
and torque idler shaft bolts
to 35 ft. lbs. (47.5 Nm).
✪
5. Repeat steps 2 and 3 to verify proper alignment.
116
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MAINTENANCE
Steering System
Steering Inspection and Adjustment
Each week, or before a long ride, check all steering system fasteners and
tighten if necessary.
✪
✪
✪
✪
✪
117
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MAINTENANCE
Steering System
Ski Alignment
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 Polaris 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 measurement
between the skis at point X should be 1/8I to 1/4I (3-6 mm) greater
than the measurement 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.
X
10I
10I
Y
118
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MAINTENANCE
Steering System
n Ski Skags
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 carbide skags than the original equipment, it may
also be necessary to add track studs to maintain proper vehicle control while
turning on hard-packed snow or ice.
Some models have one skag, others may have dual skags. Check skags
before each use of the snowmobile to ensure positive steering character-
istics. Skags must be replaced when worn to half their original diameter.
NOTE: Carbide skags must be replaced if any abnormal wear or chip-
ping is found.
Skag Replacement
1. Raise and support the front of
the machine so the skis are
approximately 6I (15.2 cm)
from the ground.
2. Remove the attaching nuts
and pry the skag downward.
3. Remove the front end of the
skag.
4. Remove the rear end of the
skag.
5. Reverse the steps to install a
skag.
119
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MAINTENANCE
Steering System
n Rail Slide Wear
Measure slide thickness at
several points along the rail.
Have your dealer replace the
slide when it's worn down to
the top of the wear limit
7/16I
(1.1 cm)
✪
indicator groove (✪). Do not
operate the snowmobile if
slide thickness measures less
than 7/16I (1.1 cm).
Suspension Maintenance
n Pre-Ride Suspension Inspection
Loose nuts and bolts can reduce your snowmobile's reliability and cause
needless repairs and 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 115.
n Check rear idler adjusting bolt locknuts for tightness.
n Check front torque arm limiter strap condition.
n Check rail slide condition. See page 120.
n Check track tension. See page 114.
n Lubricate all rear suspension components. See page 88.
n Check ski runner/skag condition. See page 119.
n Check ski spindle bolts for tightness.
n Check tie rod end nuts for tightness.
120
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MAINTENANCE
Extended Storage
Off-season or extended storage of your snowmobile requires preventive
measures to aid against deterioration and to prolong the useful life of
many components. See page 124 for the part numbers of Polaris prod-
ucts.
Cleaning and Preservation
Proper storage starts with cleaning, washing, and waxing the hood,
chassis, and plastic parts. Wipe down remaining surfaces with a damp
cloth. Clean and touch up with paint any rusted or previously painted
surfaces. Be sure that corrosive salt and acids are removed from sur-
faces before beginning preservation with waxes and rust inhibitors
(grease, oil or paint).
The machine should be stored in a dry garage or shed, out of direct sun-
light, and covered with a fabric snowmobile cover. Plastic tarp may
cause condensation to form and damage snowmobile components.
Controls and Linkage
Lubricate all bushings and cables as outlined in the Periodic Mainte-
nance Table beginning on page 85.
121
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MAINTENANCE
Extended Storage
Bearings
Grease the jackshaft and drive shaft clutch side bearings with Polaris
Premium All-Season Grease or a similar high quality grease to prevent
corrosion.
Clutch and Drive System
Remove the drive belt and store in a cool dry location. Do not lubricate
clutch components, except the driven clutch shaft bushing as outlined in
the Master Repair Manual. See your dealer.
Engine and Carburetor Protection
Proper preparation of the engine and fuel system is vital to the preven-
tion of rust 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 container.
Always add Premium Carbon Clean or a fuel conditioner/stabilizer to
the fuel tank. Follow the instructions on the container, running the
engine for five minutes to get additives through the entire fuel system.
Top off with fresh fuel. Do not allow the snowmobile to run out of fuel.
See page 74.
If stabilizer is not used, drain the carburetors by removing the water trap
drain plugs. See page 97.
NOTE: Jet restriction caused by improper storage can cause lean con-
ditions and very poor slow speed driving quality.
122
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MAINTENANCE
Extended Storage
Electrical Connections
Replace worn or frayed electrical wire and connectors. Be sure wiring
harness is properly secured away from sharp edges, steering linkage,
moving parts, and hot exhaust parts.
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. See page 29.
2. Be sure the fuel cap and oil cap are installed
correctly.
3. Always tie the snowmobile to the transporting unit securely using
suitable straps.
4. Remove the ignition key to prevent loss.
123
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POLARIS PRODUCTS
Part No.
Description
Engine Lubricants
Fogging Oil (12 oz. Aerosol)
2870791
2871098
2871097
2871240
2871721
2871722
2872347
2874438
2874439
2874443
Premium 2-Cycle Engine Oil (qt.)
Premium 2-Cycle Engine Oil (gal.)
Premium 2-Cycle Engine Oil (2.5 gal.)
Premium Gold Synthetic 2-Cycle Engine Oil (qt.)
Premium Gold Synthetic 2-Cycle Engine Oil (gal.)
Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.)
VES II Synthetic 2-Cycle Engine Oil (qt.)
VES II Synthetic 2-Cycle Engine Oil (gal.)
VES II Synthetic 2-Cycle Engine Oil (2.5 gal.)
Chaincase Lubricants
2873105
2872951
Synthetic Chaincase Lubricant (qt.)
Synthetic Chaincase Lubricant (12 oz.)
Grease/Specialized Lubricants
Grease Gun Kit, Premium All Season (3 oz.)
Premium All Season Grease (3 oz. cartridge)
Premium All Season Grease (14 oz. cartridge)
Dielectric Grease (Nyogelt)
2871312
2871322
2871423
2871329
Coolant
2871323
2871534
Anitfreeze, 60/40 Premix (gal.)
Anitfreeze, 60/40 Premix (qt.)
Additives/Miscellaneous
2871326
2870652
2872189
2872893
2870505
2872889
2872890
Carbon Clean Plus (12 oz.)
Fuel Stabilizer (16 oz.)
DOT 4 Brake Fluid (12 oz.)
Engine Degreaser (12 oz.)
Isopropyl
Brake and Clutch Cleaner
Carb and Throttle Body Cleaner
124
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TROUBLESHOOTING
Engine Troubleshooting
Unless you have experience and training in two-cycle engine repair,
see your dealer if technical problems arise.
Problem
Probable Cause Solution
Erratic engine oper- Drive clutch binding • SEE YOUR DEALER.
ating RPM during
Driven clutch mal-
function
• SEE YOUR DEALER.
• Replace the drive belt.
• SEE YOUR DEALER.
acceleration or load
variations
Harsh drive clutch
engagement
Drive belt worn or
too narrow
Excessive belt/
sheave clearance
Drive belt turns over Wrong belt for appli- • Replace the drive belt.
cation
Clutch alignment out • SEE YOUR DEALER.
of spec
Engine mount bro-
ken or loose
• Inspect and replace. SEE YOUR
DEALER.
Machine fails to
move
Clutch jammed
• Check for twisted belt or broken
spring. SEE YOUR DEALER.
Track jammed
• Foreign object may be caught or the
rail slide melted to the track clips
due to lack of lubrication.
• Track may be iced up or frozen to
the ground.
Chaincase sprocket
or chain jammed or
broken
• Chain is loose or broken or chain
tightener is loose. SEE YOUR
DEALER.
125
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TROUBLESHOOTING
Engine Troubleshooting
Problem
Probable Cause Solution
Noise in drive sys-
tem
Broken drive clutch • SEE YOUR DEALER.
components
Bearing failure/
chaincase, jackshaft,
or front drive shaft
• SEE YOUR DEALER.
Drive belt surface
flat spots
• Inspect and replace as needed.
Drive chain loose
• Inspect and adjust (or replace).
• SEE YOUR DEALER.
Drive chain worn,
sprocket teeth bro-
ken
Poor low RPM per-
formance
Worn drive belt
• Inspect and replace as needed.
• SEE YOUR DEALER.
Excessive belt/
sheave clearance
Loose torque stop
Sticky clutch
• Inspect and adjust.
• SEE YOUR DEALER.
• Use 87-91 octane fuel (or higher).
Poor fuel quality
Seized engine
Engine doesn't turn
• SEE YOUR DEALER. Seizure is a
result of poor lubrication, inade-
quate fuel supply, broken parts or
improper cooling.
Hydrostatic lock
• Fuel may have entered the crankcase
while the vehicle was standing or
being transported. SEE YOUR
DEALER to correct the cause.
Drain plug(s) are located on the
lower crankcase for emergency
draining.
126
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TROUBLESHOOTING
Engine Troubleshooting
Problem
Probable Cause Solution
Engine turns but fails Faulty ignition
to start
• Install new spark plug(s). If engine
still fails to start, check for spark. If
there's no spark, SEE YOUR
DEALER.
No fuel to engine
• Make sure the fuel valve is on.
• Use the choke. See page 69.
• Make sure the fuel tank contains
fuel.
• Ice may be in the fuel line, filter or
pump. Add isopropyl alcohol to the
fuel system.
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 problem that must be
repaired before operating. SEE
YOUR DEALER.
Engine lacks power
Fouled or defective
spark plug(s)
• Replace the plug(s).
• SEE YOUR DEALER.
• SEE YOUR DEALER.
Fuel filter (loss of
high RPM power)
Incorrect clutching
Carburetor and fuel
pump
• There is no adjustment to change
power output. SEE YOUR
DEALER.
Engine continually
backfires
Faulty plug(s)
• Change plug(s).
Carburetor / Fuel
System
• Dirt or ice may be in the fuel system
(deicer should be added to non-etha-
nol fuel at all times for assurance
against fuel line icing).
Incorrect throttle
freeplay or faulty
switch
• SEE YOUR DEALER.
Engine requires
more than normal
pulls to start
Poor fuel
• Replace with fresh winter fuel.
Not enough fuel get- • SEE YOUR DEALER.
ting to engine
Engine backfires but Spark plug wires
• Reinstall spark plug wires to the cor-
responding cylinder.
fails to start
may be on wrong
cylinder
127
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TROUBLESHOOTING
IQ Suspension Troubleshooting
Problem
Solution
Rear suspension bot-
toms too easily
• Adjust torsion spring preload to achieve proper static sag
(see page 47).
• Change torsion spring to stiffer optional spring (see your
dealer).
• Revalve rear track shock (see your dealer).
Rides too stiff in rear • Check for binding suspension shafts and grease all pivot
points.
• Adjust torsion spring preload to achieve proper static sag
(see page 47).
• Change torsion spring to softer optional spring (see your
dealer).
• Check track tension (see page 114).
Machine darts from
side to side
• Check ski alignment (see page 118).
• 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 (see page 47).
• Check rail slide/replace if worn (see page 120).
• Install Accu-Trak dual skags (see your dealer).
Front end pushes
Steering is heavy
• Check for worn skags.
• Set static sag (see page 47).
• Install single skag (see your dealer).
• Rotate RRSS to high position (see page 51).
• Make sure spindles and all steering components turn freely.
• Check ski alignment (see page 118).
• Check skags and skis for damage.
• Set static sag (see page 47).
128
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TROUBLESHOOTING
M-10 Suspension Troubleshooting
Problem
Solution
Rear suspension bot-
toms too easily
• Increase FRA position (see setup decal under hood for ini-
tial position.
• Install appropriate optional center retainer on rear track
shock (see page 55).
• Increase front track shock coil spring preload.
• Revalve rear track shock compression damping (see your
dealer).
• Check track tension (see page 114).
Rides too stiff in rear • Decrease FRA position (see setup decal under hood).
• Install appropriate optional center retainer on rear track
shock (see page 55).
• Decrease front track shock coil spring preload.
• Revalve rear track shock compression damping (see your
dealer).
• Check track tension (see page 114).
Machine darts from
side to side
• Make sure skis are aligned properly.
• Make sure spindles and all steering components turn freely.
• Check for excessive play in steering assembly (see your
dealer).
• Make sure skags are straight on skis.
• Set static sag (see page 52).
• Ensure use of Accu-Trak dual skags.
Front end pushes
Steering is heavy
• Check for worn skags.
• Check for binding suspension shafts and grease all pivot
points.
• Shorten front limiter strap.
• Install single skags (see your dealer).
• Make sure spindles and all steering components turn freely.
• Check ski alignment.
• Check skags and skis for damage.
• Decrease IFS preload.
129
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TROUBLESHOOTING
Drive Belt Troubleshooting
Belt Wear/Burn Diagnosis
Solutions
Causes
Driving at low RPM
• Drive at higher RPMs. Gear the machine down. Check
belt deflection.
Insufficient warm-up
Towing at low RPM
• 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.
• Do not tow in deep snow. Use fast, aggressive throttle
to engage clutch.
Riding with high RPM
and slow speed (8000
RPM/10 MPH)
• Lower the gear ratio. Reduce RPM. Avoid riding in
high ambient temperatures. 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 machine loose from the snow.
Poor engine performance • Check for carburetor and choke synchronization, fouled
plugs, debris in the carburetor(s) and water, ice or dirt
in the fuel tank or fuel line.
Loading machines onto
trailers
• Skis may gouge into trailers and prevent the drivetrain
from spinning properly. Use enough speed to drive the
machine completely onto the trailer. Push and pull it to
finish loading if necessary.
Clutch malfunction
• Inspect clutch components. See your dealer.
Slow, easy clutch engage- • Use fast, aggressive throttle to engage clutch.
ment
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WARRANTY
Service and Warranty Information
Obtaining Service and Warranty Assistance
Read and understand the service data and the Polaris warranty information con-
tained in this manual. Contact your Polaris dealer for replacement parts, ser-
vice or warranty. Your dealer receives frequent updates on changes,
modifications and tips on snowmobile maintenance, which may supersede
information 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 fol-
lowing 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 provided near the front of your Owner's Manual to record the
identification numbers of your snowmobile and its engine.
Polaris Customer Service
United States: 1-763-417-8650
Canada: 1-204-925-7100
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WARRANTY
Service and Warranty Information
Polaris Anti-Theft System
The Polaris anti-theft system (PATS) monitoring program is designed to aid
owners of registered snowmobiles in recovery of stolen machines.
Administration
1. Polaris snowmobile 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 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 notifying the proper owner when a unit is
recovered.
132
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WARRANTY
Limited Warranty
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-
ITED WARRANTY on all components of the Polaris snowmobile against defects in
material or workmanship. This warranty covers the parts and labor charges for repair or
replacement of defective parts that are covered by this warranty. The warranty begins
on the date of purchase. This warranty is transferable to another consumer, during the
warranty period, through a Polaris dealer.
Registration
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 registration for warranty. No verification of registration will be sent to the
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-
ment. If you have not signed the original registration and received the customer copy,
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE
ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.
Initial dealer preparation and setup of your snowmobile is very important in ensuring
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer
setup will void your warranty coverage.
Warranty Coverage and Exclusions
Limitations of warranties and remedies
This warranty excludes any failures 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 trailer transit or as a result of unauthorized service or parts. In
addition, this warranty does not cover physical damage to paint or finish, stress cracks,
tearing or puncturing of upholstery material, corrosion or defects in parts, components
or the 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 compatible with the snowmobile.
The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option,
repair or replacement of any defective materials, or components or products. THE
REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES
AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS
SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-
QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARIS-
ING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT,
NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the
exclusion or limitation of incidental or consequential damages or implied warranties, so
the above limitations or exclusions may not apply to you if inconsistent with controlling
state law.
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WARRANTY
Limitations of warranties and remedies
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR
WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-
RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations
on how long an implied warranty lasts, so the above limitation may not apply to you if
inconsistent with controlling state law.
How to Obtain Warranty Service
If your snowmobile requires warranty service, you must take it to a Polaris dealer autho-
rized to repair Polaris snowmobiles. When requesting warranty service you must
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 dealer; however, you may use any Polaris Servicing Dealer to per-
form warranty service.
Please work with your dealer to resolve any warranty issues. Your dealer will contact
the appropriate personnel at Polaris if additional assistance is needed.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty
terms will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-
ommend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
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WARRANTY
Conditions and Exclusions
In order to qualify for warranty, the product must have been properly set up and tested
by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle
Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer
sign the PDI form prior to delivery may void the warranty. Failure to provide proof of
required periodic maintenance upon request may result in denial of warranty coverage.
Use of the recommended Polaris products for lubrication and maintenance as directed by
the Owner's manual is highly recommended. Should a failure occur during the warranty
period resulting from the use of non-recommended products, warranty coverage may be
denied.
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental
conditions and/or contamination. The following items are excluded from warranty con-
sideration if the failure was due to wear or not the direct result of a defect:
Skis
Ski wear rods
Tracks
Slide rails
Suspension components
Brake components
Seat components
Clutches and components
Steering components
Batteries
Finished and unfinished surfaces
Carburetor/Throttle body components
Engine components
Drive belts
Hydraulic components
Circuit breakers/Fuses
Electronic components
Light bulbs/Sealed beam lamps
Idler wheels
Warranty applies to the product only and does not allow for coverage of personal loss.
Some items are considered "consumable," meaning they are considered part of normal
maintenance or part of completing an effective repair. The following items are excluded
from warranty coverage in the event of a warranty claim:
Spark Plugs
Filters
Fuel
Lubricants such as oil, grease, etc.
Batteries (unless defective)
Cosmetic damage/repair
Coolants
Sealants
Hotel fees
Meals
Towing charges
Mileage
Rentals/Loss of product use
Shipping/ handling fees
Product pick-up/delivery
Loss of vacation/personal time
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/contamination; improper maintenance; modified components; use
of aftermarket components resulting in failure; unauthorized repairs; repairs made after
the warranty period expires or by an unauthorized repair center; use of the product in
competition or for commercial purposes. Warranty will not apply to any product which
has been damaged by abuse, accident, fire or any other casualty not determined a defect
of materials or workmanship.
135
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WARRANTY
Polaris Second Year Engine Service Contract
Second Year Engine Service Contract is standard on all eligible new and unused snow-
mobiles that were Snow Checked through an authorized Polaris dealer during the
March/April Snow Check promotion. The free Second Year Engine Service Contract is
honored by all authorized Polaris snowmobile dealers in North America and is transfer-
able 120 days after the original purchase date, free of charge, through any Polaris snow-
mobile dealer. Coverage on Snow Check units is automatic. Although you do not
receive a warranty card, your dealership should have printed a copy of the warranty reg-
istration form. This form is your proof of warranty.
Consumer Exclusions
• Each repair visit after the first twelve months of standard warranty coverage is subject
to a $50 deductible.
• The free Second Year Engine Service Contract applies to the first 5,000 miles or two
(2) calendar years from date of purchase, whichever comes first. Tampering with the
odometer shall void all warranties/service contracts. No extensions to coverage under
this engine service contract can be given. Used snowmobiles are not eligible under
this program.
• Snowmobiles used for commercial purposes or for racing are excluded from coverage.
Coverage
Coverage for second year engine failures due to defects in materials and workmanship
will be determined by Polaris in its sole discretion. 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 of other components of the snowmobile.
• Failures caused by improper fuel or oil.
• Piston seizures, unless caused by a defective engine component.
• Failures caused due to improper adjustments.
• Failure due to unauthorized service.
• Failures due to lack of service as required in the owner's manual or Polaris updates.
This includes off-season storage as listed in the owner's manual.
• Failure due to use of unauthorized parts or modifications.
• Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,
and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and
exhaust manifolds excluding paint coverage.
• Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring
and other electrical components are excluded from coverage.
• Cooling system coverage is limited to the water pump assembly and components, fan,
fan bearings, temperature sensor, gasket and seals.
• Non wear related throttle body parts are covered. The fuel pump is covered.
• Clutches and related clutch parts, including but not limited to, the drive belt, are
excluded from coverage.
• Electrical components are excluded from coverage.
• Gearcases and transmissions are excluded from coverage.
136
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WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-
TION.
This policy does not apply to vehicles that have received authorization for export from
Polaris Industries. Dealers may not give authorization for export. You should consult an
authorized dealer to determine this vehicle's warranty or service bulletin coverage if you
have any questions.
This policy does not apply to vehicles registered to government officials or military per-
sonnel on assignment outside the country of the selling dealer's authorized location.
This policy does not apply to Safety Recalls.
How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If
you move or are traveling within the country where your vehicle was purchased, War-
ranty or Service Bulletin repairs may be requested from any authorized Polaris dealer
who sells the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should 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 the destination country before you move. Vehicles importation
rules vary considerably from country to country. You may be required to present docu-
mentation of your move to Polaris Industries in order to continue your warranty cover-
age. You may also be required to obtain documentation from Polaris Industries in order
to register your vehicle in your new country.
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen outside of the country in which
the vehicle was originally purchased, all warranty coverage will be denied.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for war-
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-
cials or military personnel on assignment outside of the country where the vehicle was
purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance (see page 131).
137
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MAINTENANCE LOG
Present this section of your manual to your dealer 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)
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MAINTENANCE LOG
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
139
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INDEX
A
D
Accessories . . . . . . . . . . . . . . . . . . 59
Adjustable Headlights . . . . . . . . . . 29
Adjustable Steering System. . . . 27-28
Air Pollution . . . . . . . . . . . . . . . . . . 5
Avalanches. . . . . . . . . . . . . . . . . . . 13
Drive Belt Installation . . . . . . . . . 110
Drive Belt Removal. . . . . . . . . . . 109
Drive Chain Tension . . . . . . . . . . 102
Driver Awareness . . . . . . . . . . . . . 12
Driveshaft Bearing. . . . . . . . . . . . . 89
Driving Downhill. . . . . . . . . . . . . . 15
Driving in Hilly Terrain. . . . . . . . . 16
Driving on Slippery Surfaces . . . . 14
Driving Responsibly . . . . . . . . . . . 19
B
Bearings. . . . . . . . . . . . . . . . . . . . 122
Brake Components. . . . . . . . . . . . 103
Brake Fluid . . . . . . . . . . . . . . . . . 104
Brake Inspection . . . . . . . . . . . . . 103
Brake Lever Travel . . . . . . . . 64, 103
Brake System Bleeding . . . . . . . . 105
Brakelight Replacement. . . . . . . . 107
Brakes . . . . . . . . . . . . . . . . . . . . . . 64
E
Electrical Connections. . . . . . . . . 123
Engine Break-In. . . . . . . . . . . . . 70-71
Engine Protection . . . . . . . . . . . . 122
Engine Safety. . . . . . . . . . . . . . . . . . 8
Engine Stop Switch . . . . . . . . . . . . 78
Environment . . . . . . . . . . . . . . . . . . 5
Exhaust System . . . . . . . . . . . . . . 101
C
Carbide Skags . . . . . . . . . . . . . . . . 61
Carburetion . . . . . . . . . . . . . . . . 76-77
Carburetor . . . . . . . . . . . . . . . . . . . 96
Carburetor Adjustments. . . . . . . . . 96
Carburetor Protection. . . . . . . . . . 122
Carburetor Water/Sediment Trap . 97
Chaincase Oil. . . . . . . . . . . . . . . 90-91
Choke. . . . . . . . . . . . . . . . . . . . . . . 89
Choke Cable. . . . . . . . . . . . . . . . . . 89
Cleaning and Preservation. . . . . . 121
Clutch Alignment Offset . . . . . . . 108
Clutch and Drive System. . . . . . . 122
Clutch Center Distance . . . . . . . . 108
Clutch Cover Warning. . . . . . . . . . 21
Clutch Safety . . . . . . . . . . . . . . . . . 17
Clutch System . . . . . . . . . . . . . . . 108
Cold Weather Drive-Away . . . . . . 17
Controls and Linkage. . . . . . . . . . 121
Coolant. . . . . . . . . . . . . . . . . . . . . . 98
Coolant Level. . . . . . . . . . . . . . . . . 98
Cooling System, Bleeding . . . . . . 100
Cooling System, Flushing . . . . . . . 99
Customer Service. . . . . . . . . . . . . 131
F
FEATURES. . . . . . . . . . . . . . . . 25-42
FRA Position, M10 . . . . . . . . . . . . 54
Front Rear Scissor Stop. . . . . . . . . 49
Front Shock Spring Preload. . . . . . 44
Front Springs . . . . . . . . . . . . . . . . . 44
Front Suspension Adjustments . 43-44
Front To Rear Coupling. . . . . . . . . 49
FRSS . . . . . . . . . . . . . . . . . . . . . . . 49
Fuel . . . . . . . . . . . . . . . . . . . . . . 73-74
Fuel Filter . . . . . . . . . . . . . . . . . . . 95
Fuel Level . . . . . . . . . . . . . . . . . . . 74
Fuel Lines . . . . . . . . . . . . . . . . . . . 95
Fuel Pump . . . . . . . . . . . . . . . . . . . 95
Fuel System Deicers . . . . . . . . . . . 74
Fuel Valve . . . . . . . . . . . . . . . . . . . 29
G
Gauge Cleaning . . . . . . . . . . . . . . . 42
General Maintenance. . . . . . . . 92-112
H
D
Handlebar Adjustments . . . . . . . . . 58
Headlight Adjustment . . . . . . . . . . 29
Headlight Bulb Installation . . . . . 106
Headlight Bulb Removal . . . . . . . 106
High Temperature Light . . . . . . . . 99
Hood Latches. . . . . . . . . . . . . . . . . 67
D.E.T.. . . . . . . . . . . . . . . . . . . . . 30-31
Digital Display. . . . . . . . . . . . . . . . 32
Disabled Operators . . . . . . . . . . . . 11
Drive Belt. . . . . . . . . . . . . . . . 17, 110
Drive Belt Adjustment. . . . . . . . . 111
Drive Belt Condition . . . . . . . . . . 109
Drive Belt Deflection. . . . . . . . . . 111
140
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INDEX
I
R
Ice and Snow Build-up . . . . . . . . . . 14
IFS. . . . . . . . . . . . . . . . . . . . . . . . . . 43
IFS Adjustment Options . . . . . . . . . 43
IFS Components . . . . . . . . . . . . . . . 43
Inadequate Snow Conditions . . . . . 18
Instrumentation . . . . . . . . . . . . . 32-42
Intake Filters . . . . . . . . . . . . . . . . . . 95
Intake Silencer . . . . . . . . . . . . . . . . 17
INTRODUCTION . . . . . . . . . . . . 4-5
Radiator Compartment Access . . . . 29
Rail Slide Wear. . . . . . . . . . . . . . . 120
Rear Rear Scissor Stop . . . . . . . . . . 50
Rear Shocks, IQ . . . . . . . . . . . . . . . 48
Rear Suspension Adjustments . 45-46
IQ . . . . . . . . . . . . . . . . . . . 47-51
M10. . . . . . . . . . . . . . . . . . 52-57
Rear To Front Coupling . . . . . . . . . 50
Recoil Rope . . . . . . . . . . . . . . . . . . 67
Recommended Maintenance. . . . . . . 7
Registration, Warranty . . . . . . . . . 133
Retainers, Optional . . . . . . . . . . . . . 55
Reverse . . . . . . . . . . . . . . . . . . . . . . 82
Reverse Warning . . . . . . . . . . . . . . 23
Rider Capacity . . . . . . . . . . . . . . . . 11
RIDER SELECT. . . . . . . . . . . . 27-28
Riding Apparel . . . . . . . . . . . . . . . . . 9
Riding Position . . . . . . . . . . . . . . . . . 9
RRSS. . . . . . . . . . . . . . . . . . . . . . . . 50
J
Jetting Guidelines . . . . . . . . . . . . . . 77
L
Low Oil Indicator Light . . . . . . . . . 75
Lubrication . . . . . . . . . . . . . . . . 88-91
M
MAINTENANCE . . . . . . . . . . 84-123
Maintenance Interval Table . . . 85-87
Maintenance Program. . . . . . . . . . . 84
Maneuverability . . . . . . . . . . . . . . . 17
MFD Battery Replacement . . . . 41-42
MFD Components. . . . . . . . . . . . . . 32
MFD Digital Display Programs 34-40
MFD Settings . . . . . . . . . . . . . . . . . 33
S
SAFETY . . . . . . . . . . . . . . . . . . . 6-24
Safety Decals . . . . . . . . . . . . . . 21-24
Safety Symbols . . . . . . . . . . . . . . . . . 6
Sag, IQ . . . . . . . . . . . . . . . . . . . . . . 47
Sag, M10. . . . . . . . . . . . . . . . . . 52-55
Seat Storage . . . . . . . . . . . . . . . . . . 29
Sediment Trap. . . . . . . . . . . . . . . . . 97
Shock Valving . . . . . . . . . . . . . . . . 44
Shocks, Rear, IQ. . . . . . . . . . . . . . . 48
Signal Words . . . . . . . . . . . . . . . . . . 6
Ski Alignment. . . . . . . . . . . . . . . . 118
Ski Pressure, M10. . . . . . . . . . . . . . 56
Ski Skags . . . . . . . . . . . . . . . . . . . 119
Slide Rail and Track Cooling . . . . . 71
Snow Conditions. . . . . . . . . . . . . . . 18
Spark Plug Condition . . . . . . . . . . . 93
Spark Plug Removal . . . . . . . . . . . . 94
Spark Plugs . . . . . . . . . . . . . . . . . . . 92
Speed. . . . . . . . . . . . . . . . . . . . . . . . 11
Spring Preload, Rear, IQ. . . . . . . . . 47
Spring Preload, Rear, M10 . . . . . . . 55
Springs . . . . . . . . . . . . . . . . . . . . . . 44
Starting the Engine . . . . . . . . . . 69-70
Starting, Emergency . . . . . . . . . . . . 81
Steering Inspection/Adjustment . . 117
Steering System . . . . . . . 66, 117-120
Stopping, Emergency . . . . . . . . . . . 80
Storage Compartment . . . . . . . . . . . 29
N
“No Passenger” Warning . . . . . . . . 22
Noise . . . . . . . . . . . . . . . . . . . . . . . . . 5
O
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Oil Filter . . . . . . . . . . . . . . . . . . . . . 94
Oil Injection System . . . . . . . . . . . . 71
Oil Level . . . . . . . . . . . . . . . . . . . . . 75
Oil Lines . . . . . . . . . . . . . . . . . . . . . 94
Oil Recommendations. . . . . . . . . . . 71
OPERATION . . . . . . . . . . . . . . 69-83
Operation Warning . . . . . . . . . . 23-24
Operator Safety. . . . . . . . . . . . . . 6-20
P
Park Brake Lever Lock. . . . . . . . . . 65
POLARIS PRODUCTS . . . . . . . . 124
Pre-Ride Checklist . . . . . . . . . . . . . 62
PRE-RIDE INSPECTIONS . . . 62-68
Pre-Ride Suspension Inspection . . 120
Pressure Cap Warning . . . . . . . . . . 21
141
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INDEX
S
V
Storage, Daily . . . . . . . . . . . . . . . . 83
Storage, Extended . . . . . . . . . 121-123
Studs . . . . . . . . . . . . . . . . . . . . . . . 60
Survival Preparation . . . . . . . . . . . 10
Suspension Coupling, IQ. . . . . . . . 49
Suspension Inspection, Pre-Ride . 120
Suspension Maintenance . . . . . . . 120
Suspension Performance Tips . . . . 46
Suspension, Front, Lubrication . . . 88
Suspension, Rear, Lubrication. . . . 88
Vehicle Identification Numbers. . . . 4
W
WARRANTY . . . . . . . . . . . . 131-134
Wear Strips . . . . . . . . . . . . . . . . . . 61
Weight Transfer. . . . . . . . . . . . . . . 51
WELCOME. . . . . . . . . . . . . . . . . . . 1
Windchill . . . . . . . . . . . . . . . . . . . . 20
T
TABLE OF CONTENTS . . . . . . . . 3
Taillight/Brakelight Replacement 107
THE PERFECT FIT . . . . . . . . . 43-61
Throttle Cable . . . . . . . . . . . . . . . . 89
Throttle Lever . . . . . . . . . . . . . 63, 79
Throttle Safety Switch. . . . . . . 63, 78
Tool Kit . . . . . . . . . . . . . . . . . . . . 112
Torque Stop . . . . . . . . . . . . . . . . . 111
Torsion Spring Tension . . . . . . . . . 48
Towing. . . . . . . . . . . . . . . . . . . . . . 83
Track . . . . . . . . . . . . . . . . . . . . . . . 66
Track Alignment . . . . . . . . . . . . . 116
Track Care for Storage. . . . . . . . . 123
Track Inspection . . . . . . . . . . . . . 113
Track Lubrication . . . . . . . . . . . . 113
Track Maintenance . . . . . . . . 113-116
Track Safety. . . . . . . . . . . . . . . . . . . 8
Track Tension . . . . . . . . . . . . 46, 114
Track Warm-Up. . . . . . . . . . . . . . . 72
Track Warning. . . . . . . . . . . . . . . . 22
Traction Products. . . . . . . . . . . . 60-61
Transporting the Snowmobile . . . 123
TROUBLESHOOTING . . . . 125-130
Troubleshooting, Drive Belt . . . . 130
Troubleshooting, Engine . . . . 125-127
Troubleshooting, IQ Suspension . 128
Troubleshooting, M10 Suspension 129
Tune-Up. . . . . . . . . . . . . . . . . . . . 112
142
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