Polaris Offroad Vehicle Widetrack LX User Manual
Pantone 426C  
Widetrak LX  
Snowmobile Owner's Manual  
for Maintenance and Safety  
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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.  
WARNING  
The engine exhaust from this product contains chemicals known to the State  
of California 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 owners. We proudly produce an exciting line of  
utility and recreational 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!  
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-  
tries Inc.  
Copyright 2009 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.  
2010 Widetrak LX Owner’s Manual  
P/N 9922310  
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
This section describes safe vehicle operation and identifies warning  
labels and their locations.  
Features and Controls. . . . . . . . . . . . . . . . . . . 26  
This section identifies the locations of your snowmobile’s controls and  
features.  
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 30  
This section explains how to tailor the suspension and other features for  
an optimum riding experience.  
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 38  
This section explains procedures that must be performed before riding.  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45  
This section explains proper engine break-in, operation of features and  
general operating procedures.  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 59  
This section defines your role, and your dealer’s role, in your snowmo-  
bile’s regular maintenance.  
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 103  
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 104  
This section is a quick reference guide to solving general problems.  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109  
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 118  
Record maintenance and service in the log for your reference and for  
future owners of the vehicle.  
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122  
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INTRODUCTION  
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 the snowmobile is  
sold.  
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 sponsored by local or state organizations.  
Follow the maintenance program outlined in this manual. Preventive  
maintenance ensures that critical components of the snowmobile are  
inspected by your dealer at specific mileage intervals.  
You and your dealer must complete the registration form included with  
your snowmobile and forward it to us. This completed form is necessary  
to ensure warranty coverage.  
Protect and preserve your right to ride by joining your local trail riding  
clubs.  
Some of the illustrations and photos used in this manual are general rep-  
resentations. Your model may differ.  
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INTRODUCTION  
Preservation of the Environment  
Polaris is committed to supporting an environmental education cam-  
paign. We encourage state and provincial governments across the snow-  
belt to adopt rigorous safety training programs that encourage protection  
of our environment, including wildlife and vegetation.  
Snowmobile clubs and other organizations are working together to 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 welcome  
to non-snowmobilers, so you have a responsibility to operate your  
snowmobile with concern for others. We do our part by manufacturing  
quieter snowmobiles; 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.  
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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: ___________________________________________________  
(right front side of engine crankcase)  
Key Number: ___________________________________________________________  
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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 indicates a potential personal injury hazard.  
WARNING  
A WARNING indicates a hazardous situation which, if not avoided, may result in  
death or serious injury.  
CAUTION  
A CAUTION indicates a hazardous situation which, if not avoided, may result in  
minor or moderate injury.  
NOTICE  
A NOTICE indicates a situation that may result in property damage.  
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SAFETY  
Operator Safety  
Follow the recommended maintenance program outlined beginning on  
page 60 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 opera-  
tion with any modifications, especially those that increase speed or power. DO  
NOT MODIFY YOUR SNOWMOBILE. The snowmobile may become aerody-  
namically 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 haz-  
ard 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.  
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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.  
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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.  
Always carry the owner’s manual on your snowmobile. For added pro-  
tection, purchase and carry the following items on your snowmobile as  
well:  
• Spare Drive Belt  
• Extra Set of Spark Plugs  
• Tow Rope  
• Winter Survival Kit  
• Trail Map  
• First Aid Kit  
• Tool Kit  
• Extra Oil  
• Fuel Deicer  
Riding Position  
Operating a snowmobile requires skill and balance for proper control.  
Rider positions may vary with experience; but under many conditions,  
the proper position is to be seated with both feet on the running boards  
and both hands on the handlebar grips for proper throttle, brake and  
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.  
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SAFETY  
Operator Safety  
Riding Apparel  
Helmet  
Wearing a helmet can prevent a severe head injury. Whenever riding a  
Polaris vehicle, always wear a helmet that meets or exceeds established  
safety standards.  
Approved helmets in the USA and Canada bear a U.S. Department of  
Transportation (DOT) label.  
Approved helmets in Europe, Asia and Oceania  
bear the ECE 22.05 label. The ECE mark consists  
4
E
of a circle surrounding the letter E, followed by  
the distinguishing number of the country which  
has granted approval. The approval number and  
serial number will also be displayed on the label.  
051039  
0006.31  
Eye Protection  
Do not depend on eyeglasses or sunglasses for eye protection. When-  
ever riding a Polaris vehicle, always wear shatterproof goggles or use a  
shatterproof helmet face shield. Polaris recommends wearing approved  
Personal Protective Equipment (PPE) bearing markings such as VESC  
8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.  
Clothing  
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 22.  
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.  
11  
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SAFETY  
Operator Safety  
Cargo Overload  
Too much weight on the rear of the snowmobile may reduce your ability  
to steer. Do not exceed carrier and rack weight limits, and do not allow a  
passenger to sit on the seat back or the cargo carrier.  
Disabled Operators  
Safe operation of this rider-active vehicle requires good judgement and  
physical skills.  
WARNING! Operators with cognitive or physical disabilities have an increased  
risk of loss of control, which could result in serious injury or death. Do not allow  
disabled persons to operate this vehicle.  
Rider Capacity  
Driving 1-Up - Some Polaris snowmobiles are designed for a single  
rider only. A label on the console of these models indicates single rider  
operation.  
Driving 2-Up - Some Polaris snowmobiles are designed for up to two  
riders. A label on the hood of these models indicates that the vehicle is  
designed for one operator and one passenger only. See page 23 for label  
location.  
Snowmobiles designed for two riders should never be operated with  
more than two people on board. When traveling with a passenger, it’s  
the driver’s responsibility to operate the snowmobile safely.  
Slow down! Control becomes more difficult with two people on board.  
More space is required to make turns, and longer distances are necessary  
for stopping.  
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SAFETY  
Operator Safety  
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.  
Observe all state and local laws governing snowmobile operation.  
They’ve been established for your protection.  
Always be alert and pay attention to the trail ahead. Multiplying speed  
(MPH) by 1.5 will equal the approximate number of feet per second  
your snowmobile travels. If your speed is 40 MPH, your snowmobile is  
traveling about 60 feet per second. If you look back for only two sec-  
onds, your snowmobile will travel about 120 feet. If your speed is 60  
MPH, your snowmobile 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 snowmobile to a stop in the distance illu-  
minated by the headlight.  
13  
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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 snowmobile will drown  
out the sound of approaching vehicles.  
Look ahead, behind, and to both sides  
before turning or crossing railroad tracks  
or highways. 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. Always check with local residents or authorities for general  
information on conditions when traveling on lakes and streams that are  
strange to you. Before riding your snowmobile on a frozen body of  
water, be sure the ice is thick enough to support the snowmobile and its  
operator, as well as the force created by a moving vehicle. You may  
drown if you and the snowmobile break through the ice.  
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 sponsored by local or state organizations.  
14  
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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 the American  
and Canadian online avalanche centers at www.avalanche.org.  
15  
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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  
snowmobile, resulting 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, check for ice and snow build-up that may be obstructing  
the steering linkage. Snow screens and bib kits are available through  
your dealer to help reduce snow and ice build-up.  
Driving on Slippery Surfaces  
WARNING! Never attempt an abrupt change of direction when operating on  
slippery surfaces. 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.  
16  
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SAFETY  
Operator Safety  
Driving on Slopes  
WARNING! Climbing a hill or crossing the face of a slope may result in loss of  
balance and snowmobile rollover, 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 snowmobile to  
maintain proper balance and avoid possible rollover.  
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 snowmobile 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 snowmobile, pull the rear of the snowmobile  
around and point the front end and skis downhill. Remount the snowmo-  
bile, restart the engine, release the parking brake, and descend the hill  
carefully.  
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SAFETY  
Operator Safety  
Driving Downhill  
When riding downhill, shift your weight to the rear of the snowmobile  
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  
snowmobile 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.  
Clutch Guard  
Do not operate the engine with the clutch guard removed.  
The clutch guard is designed to protect the operator from metal parts if  
the clutch should fail. Although the chance of failure is extremely  
remote, don’t defeat the purpose of the guard by removing it. It’s pro-  
vided for your safety.  
Drive Belt  
Do not operate the engine with the drive belt removed.  
Any servicing that requires operation without a belt must be performed  
by your dealer.  
CAUTION! Operation of the engine with the belt removed may result in  
personal injury or damage to the engine.  
18  
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SAFETY  
Operator Safety  
Intake Silencer  
Do not operate the engine with the intake silencer or filter removed.  
NOTICE: 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 preci-  
sion balancing and create an unstable condition.  
Cold Weather Drive-Away  
Whenever your snowmobile has been parked for a length of time, espe-  
cially overnight, always make sure the skis and track are loosened from  
ice and snow before attempting to drive. Apply the throttle with enough  
authority to put the snowmobile into motion, but always operate within  
safety limits and, on 2-up snowmobiles, with respect for a passenger.  
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  
snowmobiles designed to carry a load or a passenger.  
19  
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SAFETY  
Operator Safety  
Inadequate Snow Conditions  
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 snowmobile.  
WARNING! Inadequate cooling and lubrication will lead to overheating of the  
slide rail and track, causing premature wear, damage and failure, which can  
result in serious injury. Reduce speeds and frequently drive into fresh snow to  
allow adequate cooling and polishing of the slide rail and track surfaces. Avoid  
operating for prolonged periods on ice, hard-packed surfaces or roads.  
Operating in Deep Snow  
If the snowmobile becomes stuck in snow, clear the running board area  
of snow, then step down the snow in front of the snowmobile so that  
when the throttle is opened, the snowmobile will be able to climb up and  
over the snow.  
20  
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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 snowmobile 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 snowmobile 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 to use your snowmobile, know the  
extent of their operating skills. Check to see if they’ve taken a snow-  
mobile safety course and have an operator’s certificate. For their pro-  
tection, as well as yours, make sure they take a snowmobile safety  
course. Everyone can benefit from the course.  
• Don't "jump" your snowmobile over large drifts or similar terrain.  
Jumping may injure your back because of spinal compression that  
could occur when the snowmobile impacts the ground. The seat and  
suspension of your snowmobile have been designed to provide pro-  
tection under normal riding conditions. Your 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.  
21  
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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)  
Wind  
Speed  
in  
Actual Thermometer Reading (_F)  
40 35 30 25 20 15 10 -5 -10 -15 -20 -25 -30 -35 -40 -45  
Equivalent Temperature (_F)  
-5 -10 -15 -20 -25 -30 -35 -40 -45  
-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63  
5
0
MPH  
Calm 40 35 30 25 20 15 10  
5
0
5
36 31 25 19 13  
7
3
0
1
10  
15  
20  
25  
30  
35  
40  
45  
50  
55  
60  
34 27 21 15  
32 25 19 13  
30 24 17 11  
9
6
4
3
1
0
-4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72  
-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77  
-2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81  
-4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84  
-5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87  
-7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89  
29 23 16  
28 22 15  
28 21 14  
27 20 13  
26 19 12  
26 19 12  
25 18 11  
25 17 10  
9
8
7
6
5
4
4
3
-1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91  
-2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93  
-3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95  
-3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97  
-4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98  
Frostbite in >> 30 min. 10 min. 5 min.  
WIND CHILL CHART (°C)  
Wind  
Speed  
in  
Actual Thermometer Reading (_C)  
5
2
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46  
Equivalent Temperature (_C)  
KPH  
Calm  
8
5
3
2
1
0
2
0
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46  
-4 -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57  
16  
24  
32  
40  
48  
56  
64  
72  
80  
88  
96  
-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62  
-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65  
-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67  
-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69  
-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70  
-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72  
-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73  
-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74  
-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75  
-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76  
-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77  
Frostbite in >> 30 min. 10 min. 5 min.  
22  
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SAFETY  
Safety Labels and Locations  
Warning labels have been placed on the snowmobile for your protection.  
Read and follow the instructions of the labels and other warnings on the  
snowmobile carefully. If any of the labels depicted in this manual differ  
from the labels on your snowmobile, always read and follow the instruc-  
tions of the labels on the snowmobile.  
If any label becomes illegible or comes off, contact your Polaris dealer  
to purchase a replacement. Replacement safety labels are provided by  
Polaris at no charge. The part number is printed on the label.  
Clutch Cover Warning  
This warning label is found under the hood on the clutch cover:  
WARNING  
Do not operate engine with hood open.  
Do not attempt adjustment with engine running.  
Do not operate engine with this guard open.  
Never run engine with drive belt removed.  
Never service clutches yourself - see your dealer.  
Air Box Warning  
This warning label is found under the hood on applicable models:  
CAUTION  
Do not operate above 40 mph with hood-to-air box foam removed  
or engine failure will result.  
Passenger Warning  
+
Your Polaris Widetrak snowmobile is  
designed for the operator and one pas-  
senger. For more information on oper-  
ating with a passenger, see Page 12.  
WARNING  
This vehicle is designed for opera-  
tor and ONE passenger  
23  
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SAFETY  
Safety Labels and Locations  
Track/Seat Warning  
+
The track/seat warning label is on the  
rear of the tunnel:  
WARNING  
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.  
Reverse Warning  
Polaris Widetrak snowmobile is  
equipped with standard reverse.  
The reverse warning label is  
located above the instrument hous-  
ing.  
+
WARNING  
Reverse operation, even at low  
speeds, can cause loss of con-  
trol resulting in serious injury  
or death. To avoid loss of con-  
trol, always:  
• Look behind before and while  
backing up.  
• Avoid sharp turns.  
• Shift to or from reverse only when stopped.  
• Apply throttle slowly.  
NOTE: For more information, see Owner's Manual.  
24  
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SAFETY  
Safety Labels and Locations  
Operation Warning  
An operation warning label is present on the console of all Polaris snow-  
mobiles:  
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 the 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.  
25  
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FEATURES AND CONTROLS  
General Representation  
5
4
6
7
3
8
9
2
1
10  
1. Fuel Filler Cap (may include a fuel gauge)  
2. Ignition Switch  
3. Brake Lever  
4. Speedometer (may include indicator/warning lights)  
5. Reverse Indicator  
6. Mountain Bar  
7. Engine Stop Switch (see page 54)  
8. Throttle Control  
9. Choke  
10. Recoil Starter Handle  
26  
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FEATURES AND CONTROLS  
Some Polaris snowmobiles are  
equipped with special features.  
Controls for these features are  
illustrated on this page. Not all  
models come with these features.  
Refer to your Owner’s Manual  
Supplement.  
4
5
3
2
1. Headlight Dimmer Switch  
2. Parking Brake Lock  
3. Handlebar Grip Warmer  
Switch  
1
4. Thumbwarmer Switch  
5. Electronic Reverse Button  
Fuel Valve  
The fuel valve is located under the  
hood. Turn the fuel valve off when-  
ever the snowmobile is stored or  
parked.  
1. Turn the valve clockwise to  
turn off the fuel supply.  
2. Turn the valve counter-clock-  
wise to turn on the fuel supply.  
OFF  
ON  
27  
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FEATURES AND CONTROLS  
4
6
5
3
2
7
8
1
9
10  
11  
12  
14  
15  
13  
1. Hood  
2. Headlight  
3. Windshield  
4. Handlebar  
5. Operator Seat  
6. Passenger Hand Hold Strap  
7. Cargo Rack  
8. Taillights  
9. Snow Flap  
10. Track  
11. Suspension  
12. Trailing Arm  
13. Nosepan  
14. Front Bumper (do not use for pulling or dragging the snowmobile)  
15. Skis  
28  
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FEATURES AND CONTROLS  
Backrest  
The backrest is adjustable  
for either operator or pas-  
senger use.  
Raise/Lower  
1. Loosen the upper  
adjustment knobs to  
raise or lower the  
backrest.  
2. Loosen the lower  
adjustment knobs to  
move the backrest for-  
ward for operator use  
or rearward for pas-  
senger use.  
3. Always tighten the  
knobs.  
Operator/Passenger  
Cargo Rack  
Always secure cargo before operating. Do not exceed the rack weight  
limit specified on the cargo rack label. Do not allow a passenger to sit on  
the seat back or the cargo rack.  
29  
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THE PERFECT FIT  
Front Suspension Adjustments  
Break in the suspension for approximately 150 miles (240 km) and re-  
grease all suspension parts 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 snowmobile should be methodically tested  
under the same conditions after each adjustment (trail and snow condi-  
tions, vehicle speed, riding position, etc.) until the best ride is achieved.  
Adjustments should be made to one area at a time in order to properly  
evaluate the change.  
IFS Components  
1. Skis  
2. Front shocks and springs  
3. Rod ends  
4. Trailing arms  
4
2
IFS Adjustment Options  
• Front shock spring preload  
• Optional springs  
1
3
30  
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THE PERFECT FIT  
Front Suspension Adjustments  
Always verify ski alignment before making adjustments to the IFS. See  
page 92 to check alignment. If the skis are misaligned, see your dealer,  
as the camber adjustment may also be affected.  
The tension at which the shock coil spring is set is called spring preload.  
For the best ride, the spring preload should be set as low as possible to  
use the full travel of the ski shock, with occasional light bottoming. To  
determine if your snowmobile is using full travel of the ski shock, push  
the jounce bumper down as far as it will go on the shock rod and test  
ride the snowmobile. The bumper will move up on the rod in direct rela-  
tion to the amount of travel. If the shock travel is full, the bumper will  
be seated at the top of the shock.  
Shock Components  
1
1. Retainer  
2. Shock Rod  
2
3. Jounce Bumper  
4. Body  
3
5. Spring Preload Adjuster Nut  
4
5
31  
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THE PERFECT FIT  
Front Suspension Adjustments  
Shock Spring Preload  
Increasing spring preload  
will increase ski-to-ground  
pressure. Decreasing spring  
preload will decrease ski-  
to-ground pressure.  
Front Springs  
For models without exter-  
nally adjustable or revalv-  
able shocks, the front  
springs can be changed if  
spring preload alone isn’t  
sufficient and further  
adjustment is desired to  
control suspension stiff-  
ness. Special tools are  
required to adjust front  
springs. If you feel that  
your front suspension needs  
adjustment see your Polaris  
dealer for more informa-  
tion.  
Front Shock Washers  
32  
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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 condi-  
tions. However, all suspension designs and adjustments involve a com-  
promise, or trade-off. For example, a suspension set up for snow-cross  
racing would provide a very stiff ride on the trail. A suspension set up  
for trail riding would bottom out harshly on a snow-cross course.  
See your Polaris dealer for initial suspension setup information. Addi-  
tional 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.  
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 set-up. These  
adjustments are easy to make, involve very little time or effort, and  
greatly affect the ride.  
• In deep snow, a new rail slide will offer improved performance over a  
worn rail slide. It can also improve top speed.  
• When riding on ice or hard-packed snow, adding a set of bogie wheels  
to the rail may enhance the snowmobile’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.  
Tip: 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. See  
page 65.  
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 88.  
33  
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THE PERFECT FIT  
WideTrak Rear Suspension Adjustments  
Rear Spring Settings  
Rear spring adjustment is primarily a control for riding comfort. To  
check for the recommended settings:  
1. Lift the rear of the snowmobile to relieve the rear springs.  
2. Slowly lower the snowmobile and measure the distance between the  
ground and the running board.  
3. Without letting the suspension settle, the rider should carefully  
mount the snowmobile.  
4. Measure the distance between the ground and the same spot on the  
running board.  
The difference between the two measurements should be approximately  
1 1/2" (3.8 cm). If the difference is greater than 1 1/2", the rear spring  
should be adjusted equally on both sides until the desired 1 1/2" drop is  
obtained.  
Compensating adjustments for heavy or light drivers or cargo loads can  
be made by adjusting the rear spring eye bolt length. Adjust spring ten-  
sion so there is equal tension on the long leg of each spring.  
Eye Bolt  
Tip: Rear spring settings will affect ski-to-ground pressure. If ski pressure is too  
light it may be desirable to tighten the rear springs for an increase in ski-to-  
ground pressure.  
34  
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THE PERFECT FIT  
Handlebar Adjustments  
Standard Handlebar  
Follow these steps to adjust handlebar angle at the handlebar block.  
1. Remove the mountain bar by  
Bar  
removing nuts.  
2. Using a 7/16-inch wrench,  
loosen the four nuts on the  
bottom of the adjuster block  
(turn the handlebar either left  
or right for access to the rear  
nuts). If necessary, pry the  
blocks apart with a screw-  
driver.  
Bolts  
Nuts  
3. Adjust the handlebar to the  
desired angle. Be sure the  
handlebar, brake lever and  
throttle lever operate  
Nuts  
smoothly and do not hit the  
gas tank, windshield or any  
other part of the snowmobile  
when the handlebar is turned  
fully to the left or right.  
4. Torque the front bolts first, then torque the rear bolts. Torque the  
bolts to 11-13 ft. lbs. (15-18 Nm).  
5. Reinstall the mountain bar.  
35  
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THE PERFECT FIT  
Traction Products  
n Carbide 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.  
Inspect skags frequently. Worn skags may reduce steering and braking  
control on hard-packed snow and ice. Replace worn skags to maintain  
proper balance and vehicle control.  
WARNING! Loss of control can result in serious injury or death. Proper balance  
of traction products on the skis and track must be maintained to obtain proper  
vehicle control on hard-packed snow or ice. See your dealer for assistance.  
36  
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THE PERFECT FIT  
Accessories  
Polaris offers a wide range of accessories for your snowmobile. From  
map light to electric start, Polaris has the accessories that will help make  
each ride more enjoyable. See your dealer for a list of accessories.  
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 to, but is not limited to the following areas: brakes,  
clutches, fuel systems, and exhaust systems.  
Exhaust systems are critical safety areas that must use approved Polaris  
parts. Please see your Polaris dealer for service.  
37  
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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 refer-  
enced 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  
81, 84  
42  
43  
Parking Brake Lock/Brake Lever/Brake System  
Auxiliary Shut-Off Switch (Engine Stop Switch)  
Ignition Switch  
40, 41, 75  
54  
44  
Taillight/Brakelight/Headlight  
Suspension Mounting Bolts  
Skags (Wear Bars)  
44  
94  
93  
Ski Saddle and Spindle Bolts  
Hood Straps/Latches  
94  
43  
Throttle Lever/Safety Switch  
Rear Wheel Idler Bolts  
39, 54, 55  
89, 94  
42, 90  
94  
Track Alignment/Condition  
Rail Slide Condition  
Chaincase Oil Level  
67  
Injection Oil Level  
51  
38  
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PRE-RIDE INSPECTIONS  
Before Starting the Engine  
Before starting the engine, always refer to all safety warnings pertaining  
to snowmobile operation. Never start the engine without checking all  
vehicle components to be sure of proper operation.  
WARNING! Operating the vehicle with worn, damaged, or malfunctioning  
components could result in serious injury or death. Never start the engine  
without checking all vehicle components to be sure of proper operation.  
n 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. See page 55.  
n Throttle Safety Switch  
Test the throttle safety switch system before the snowmobile is operated.  
See page 54.  
39  
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PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Hydraulic 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 handgrip  
than 1/2 inch (1.3 cm). A smaller  
distance indicates low brake fluid  
1/2 inch (1.3 cm)  
level or air in the hydraulic sys-  
tem. See pages 76-77 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.  
Check for the presence of air in the fluid system. See pages 76-77 or see  
your dealer for service.  
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  
serviced at the first sign of sponginess.  
40  
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PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Parking Brake Lever Lock  
Your snowmobile may have a  
parking brake lever lock located  
over the brake lever. Use the  
brake lever lock only when you  
want the snowmobile to remain  
stationary; for example, when  
parked on an incline for a period  
of five minutes or less.  
3
4
2
1
1. Brake Lever  
2. Parking Brake Lever Lock  
3. Master Cylinder Reservoir/  
Cover  
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.  
NOTICE: 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 will illuminate if the parking brake lever lock is set  
while the engine is running. It will also illuminate when the service  
brake is in use. If the parking brake light does not come on when the  
parking brake or service brake is in use, have it serviced by your dealer.  
Lock Release  
To release the lock, squeeze the brake lever tightly. The lock will return  
to the unlocked position.  
WARNING! If the parking 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.  
41  
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PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Steering System  
Manually turn the skis completely to the right and to the left. If any dif-  
ficulty is encountered, check for ice and snow build-up that may be  
obstructing the steering linkage. Make sure all greasable components  
are properly lubricated.  
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.  
WARNING! Use of traction products such as studs increases the possibility of  
track damage and/or failure. Driving at high speeds for extended periods of time  
with 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.  
Track damage or failure caused by operation on ice or under poor lubri-  
cation conditions voids the track warranty.  
42  
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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 Seat Latches  
If your snowmobile is equipped with a removable seat, ensure that the  
seat latches are securely in place before every use of the snowmobile.  
n Recoil Rope  
Inspect the recoil rope and handle for excessive wear, and make sure the  
knot securing the rope inside the handle is secure. If excessive wear is  
found, see your Polaris dealer for replacement.  
n Transmission  
Make sure the transmission is not in reverse before starting the engine  
(if equipped with reverse).  
43  
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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 Lighting  
Check the headlight (high and low beam), taillight, and brake light.  
Replace burned out lamps before operating.  
n Mirrors (if equipped)  
Adjust the mirrors so they can be used to their full advantage.  
n Operating Area  
Before driving, check your surroundings. Be aware of obstacles and  
make sure bystanders are a safe distance from the snowmobile.  
n Ignition Switch  
Make sure the engine stops when the ignition switch is turned to OFF.  
44  
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OPERATION  
Starting the Engine  
NOTICE: Engaging the starter when the engine is running WILL result in serious  
engine damage, especially if the transmission is in reverse. Never  
engage the starter when the engine is running.  
1. Turn the fuel valve on. See  
CHOKE POSITIONS  
page 27.  
2. Turn the key to the ON  
OFF  
position.  
3. Pull the engine stop switch  
up to the RUN position.  
HALF ON  
FULL ON  
4. If starting a cold engine,  
flip the choke toggle to  
FULL CHOKE. Do not  
use the choke if starting a  
warm engine. Do not  
depress the throttle until  
the engine starts.  
5. If equipped with electric start, turn the key to START to crank the  
engine. Release the key to the ON position when the engine starts.  
NOTICE: Don’t pull the starter rope to the fully extended position and don’t allow  
it to snap back into the housing. Damage may result. To avoid engine  
damage, do not operate the electric starter or pull-rope starter while  
the engine is running.  
6. If not equipped with electric start, grasp starter handle and pull  
slowly until the recoil engages, then pull abruptly to crank the  
engine.  
7. Repeat the cranking procedure as needed until the engine starts.  
8. 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 CHOKE position.  
45  
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OPERATION  
Engine Break-In  
No single action on your part is as important to long, trouble-free snow-  
mobile life as proper break-in of a new or rebuilt engine. Premix the  
first tank of gasoline with one pint of Polaris injection oil for each five  
gallons of fuel. This, in addition to the lubrication supplied by the injec-  
tion system, will assure proper engine break-in.  
NOTICE: 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 openings and vehicle 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  
snowmobile.  
46  
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OPERATION  
Engine Break-In  
Oil Injection System  
Always check and fill the oil tank when refueling. See page 50.  
NOTICE: 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  
Engine lubrication comes from oil added to the fuel and oil injection  
systems. Polaris recommends the use of Premium 2-Cycle Oil for this  
engine. See page 103 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  
NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide  
rail and track, resulting in premature wear and failure. Reduce speeds  
and frequently 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.  
47  
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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 snowmobile and the moving track. Never hold the snowmobile up  
or stand behind it while warming up the track. Do not use excessive throttle dur-  
ing warm-up or when the track is free-hanging. Be sure the rear support is sta-  
ble.  
WARNING  
Use of traction products such as studs, ice growsers, etc. will increase the possi-  
bility 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 support the rear of the snow-  
mobile at the rear bumper. The track should be approximately 4  
inches (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.  
Tip: It will take longer to warm up the track sufficiently during colder outdoor  
temperatures.  
4. Release the throttle, apply the brakes, shut off the engine and lower  
the snowmobile to the ground.  
5. Grasp the skis by their front loops and move them from side to side.  
This will loosen frozen snow from the ski bottoms, allowing the  
snowmobile to move forward more easily.  
6. The engine, drive system and track are now properly warmed up  
and the snowmobile may be driven following normal safety prac-  
tices.  
48  
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OPERATION  
Fuel  
Fuel Safety  
WARNING  
Gasoline is highly flammable and explosive under certain conditions.  
• Always exercise extreme caution whenever handling gasoline.  
• Always refuel with the engine stopped, and outdoors or in a well  
ventilated area.  
• Do not overfill the tank. Do not fill the tank neck.  
• Do not smoke or allow open flames or sparks in or near the area where refu-  
eling 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 can-  
cer, birth defects or other reproductive harm. Operate this vehicle only outdoors  
or in well-ventilated areas.  
49  
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OPERATION  
Fuel  
Your Polaris engine is designed to run on 87 octane non-oxygenated or  
89 octane oxygenated pump gasoline. There’s a great deal of variability  
in the quality of the 87 octane gasoline available, so we encourage the  
use of premium fuel when possible. Do not use lower than 87 octane  
fuel. Do not use fuel containing more than 10% ethanol (including E85).  
NOTICE: Using fuels with a lower than recommended octane or operating with  
obstructed fuel systems will result in serious and costly engine  
damage. Always use the recommended fuels for your snowmobile.  
Fuel Reserve Capacity (Mechanical Gauge)  
There are approximately two gallons of fuel left in the tank when the  
mechanical fuel gauge reads RES.  
Fuel System Deicers  
If you use non-oxygenated fuel, Polaris recommends the regular use of  
isopropyl-based fuel system deicer or Polaris Carbon Clean Plus. Add  
one to two ounces per gallon (8-16 milliliters per liter) of gasoline to  
prevent engine damage resulting from fuel system icing and lean fuel  
mixtures. Never use deicers or additives containing methanol. See page  
103 for the part numbers of Polaris products.  
If you use oxygenated fuel containing ethanol, additional alcohol deic-  
ers or water absorbing additives are not required and should not be used.  
NOTICE: Prolonged exposure to petroleum based products may damage paint.  
Always protect painted surfaces when handling fuel.  
50  
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OPERATION  
n Oil  
Low Oil Indicator Light  
The low oil indicator light will indicate when to add oil. See page 47 for  
oil recommendations.  
When the low oil indicator light is on, oil should be added before further  
operation of the snowmobile. Visually check the oil level in the bottle.  
The engine may be operated as long as oil is visible in the oil tank. If oil  
is not visible, continued operation may cause serious engine damage.  
Never mix brands of oil. Serious chemical reactions can cause injection  
system blockage, resulting in serious engine damage. They may also be  
incompatible and the result could be sludge formation, filter blockage,  
and reduced cold weather flow rates. All Polaris oils are compatible  
with each other.  
Always maintain the oil level above the tank’s low level line. This is  
especially important when the snowmobile is operated in mountainous  
terrain. Maintaining the proper oil level will prevent system aeration and  
possible loss of pumping action, which could result in engine damage.  
NOTICE: Mixing brands or using a non-recommended oil may cause serious  
engine damage. We recommend the use of Polaris 2-cycle oils for  
your snowmobile. Never mix brands.  
Operating the snowmobile without proper engine lubrication can result  
in serious engine damage. Always check the oil level when refueling.  
51  
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OPERATION  
n Oil  
Low Oil Level  
Always do a visual check of the oil level when refueling. When the oil  
reaches the low level mark, add one U.S. quart of recommended oil to  
the tank. See page 47 for oil recommendations.  
The Polaris oil cap on the oil tank may be vented to allow proper oil  
flow. See your Polaris dealer for recommended replacement parts.  
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.  
CAUTION! Improper carburetor adjustments may result in operator safety  
hazards as well as serious engine damage. Always have your Polaris dealer  
perform any carburetor adjustments.  
52  
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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.  
RMK carburetors are preset to operate at altitudes of 6000-8000 feet  
(1800-2400 m) above sea level (see page 72 for more information). Car-  
buretors 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.  
NOTICE: A main jet that’s too small will cause a lean operating condition and  
may cause serious engine damage. Jet the carburetors carefully for  
elevation and temperature according to the jetting charts. Refer to  
your Owner’s Manual Supplement.  
It’s the owner’s responsibility to ensure that the correct jets are installed  
in the snowmobile for a geographical area. Be very careful 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 encountered.  
53  
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OPERATION  
n Engine Stop Switch  
Push down on the engine  
stop switch to stop the  
engine in an emergency.  
This will ground out the  
ignition and bring the  
engine to a quick stop.  
To restart the engine, the  
switch must be pulled up  
to the ON position.  
Stop Switch  
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. Test the throttle  
safety switch system daily before operation.  
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 pres-  
sure on the pivot pin in the direction shown in the illustration.  
4. Apply a slight amount of throttle. A properly functioning switch  
must shut down the engine.  
54  
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OPERATION  
n Throttle Lever  
WARNING! An improperly functioning throttle lever may cause erratic  
snowmobile 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(s) 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.  
Tip: Excessive free play in the throttle cable may cause the safety switch to acti-  
vate, preventing the engine from starting. If this occurs, return the snowmo-  
bile 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  
snowmobile with the throttle safety switch disconnected. Return the  
snowmobile to an authorized Polaris dealer for service as soon as possi-  
ble.  
55  
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OPERATION  
n Emergency Stopping  
The following chart lists methods for stopping the snowmobile in the  
event of an emergency. Refer to page 54 for more information about the  
engine stop switch and throttle safety switch.  
THROTTLE  
CONDITION  
SYSTEM  
WHAT IT DOES  
Ignition Switch  
Brake  
Interrupts ignition circuit  
Slows jackshaft  
All  
All  
Choke  
Floods engine  
Half throttle or less  
Engine Stop Switch  
Throttle Safety Switch  
Interrupts ignition circuit  
Interrupts ignition circuit  
All  
All  
Emergency Starting  
Your snowmobile is equipped with a tool kit containing essential tools  
for emergency use. Snowmobiles equipped with electric start have a  
recoil for emergency starting. If the recoil starter system fails, an emer-  
gency start strap is provided in the kit.  
56  
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OPERATION  
Reverse Operation  
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.  
Mechanical Reverse  
Make sure the shift lever is shifted completely into forward or reverse  
position. Some models are equipped with a reverse indicator light that  
will help you make that determination.  
Do not force the shift lever into reverse if resistance is felt. The gears  
may not always be aligned for shifting into reverse, and forcing the lever  
may cause damage. If resistance is felt, gently apply the throttle to move  
the gears to a different position and try to shift again.  
The transmission may not always be in the gear indicated by the shift  
lever. Apply the throttle slowly until you're sure which gear is engaged.  
Sometimes the drive belt will drag in the drive clutch, causing slight  
tension in the transmission and making it hard to shift. Shutting the  
engine off will remove this tension and ease shifting. This should only  
happen during the break-in of a new belt or when the drive/driven clutch  
center distance is too long. If this is the case, belt tension adjustments  
should be made by your dealer.  
57  
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OPERATION  
Towing  
Do not use the front bumper to pull or drag the snowmobile. The front  
bumper is not designed for this type of use and may detach from the  
vehicle if force is applied.  
For your safety, do not attempt to using the tow hitch until you’ve read  
the following warnings and understand the proper hitch functions.  
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 person  
riding in the towed object. Braking distances increase when towing loads. Slow  
down to maintain control 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 a rider on the towed  
snowmobile to operate the brake and steering when necessary.  
NOTICE: Towing a disabled snowmobile with the drive belt in place can result in  
serious damage to the engine and drive system. Always remove the  
drive belt from a disabled snowmobile before towing.  
58  
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MAINTENANCE  
Emission Control Information  
Any qualified repair shop or qualified person may maintain, replace, or  
repair the emission control devices or systems on your snowmobile.  
Emission Control Label  
Your snowmobile is equipped at the time of sale with an emission con-  
trol information (ECI) label and a factory-installed emissions informa-  
tion hangtag. These items are required by U.S. Environmental  
Protection Agency regulations. The ECI label is permanently affixed to  
either the right side of the tunnel or the engine recoil cover. The ECI  
label should not be removed, even after you purchase the snowmobile.  
You may remove the factory-installed emissions information hangtag,  
which is intended solely for your use in making a purchasing decision.  
Emission Control Maintenance Requirements  
Your snowmobile is certified to operate on gasoline with a minimum  
octane level of 87 (R+M)/2. If your snowmobile is equipped with a  
check engine light and it comes on, you must take your snowmobile to a  
qualified dealer for diagnostic service. Specifications and adjustments  
for engine tune-ups are located in the Service Manual, which is avail-  
able to your qualified service technician. Reverse (if equipped) must not  
be engaged during engine tune-ups.  
Owner's Responsibilities  
Please read the Snowmobile Engine Emissions Limited Warranty, and  
read the maintenance section of your owner's manual. You are responsi-  
ble for ensuring that the specified maintenance is performed. Polaris  
recommends that you contact an authorized Polaris dealer to perform  
any service that may be necessary.  
59  
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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 118.  
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 perfor-  
mance 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.  
NOTICE: 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.  
60  
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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  
150 mi.  
500 mi.  
1000 mi.  
2000 mi.  
Pre-  
(240 km) (800 km) (1600 km) (3200 km)  
Season  
CLUTCH  
Clutch Offset Alignment  
80  
I
I
I
(without belt)  
Drive Belt Condition  
Clutches (disassemble)  
Belt Tension  
81  
80  
--  
I
C
I
I
C
I
I
C
I
I
I
I
Clutch Sheaves  
84  
I
I
I
ENGINE  
Engine Mounts  
--  
43  
--  
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
I
I
I
Recoil Rope  
Engine Mounting Plate  
Engine Torque Stop  
Cylinder Head Bolts  
Cylinder Base Nuts  
Ignition Timing BTDC  
Spark Plug Condition  
Exhaust Pipe  
84  
--  
I
--  
I
I
--  
68  
74  
74  
I
I
I
Exhaust Retaining  
Springs  
I
I
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  
75  
--  
Brake Disc  
Parking Brakes  
Brake System  
Brake fluid  
41  
40,75  
76  
R
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)  
C - Clean R - Replace L - Lubricate  
61  
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MAINTENANCE  
Periodic Maintenance Interval Table  
Item  
See  
Page  
Frequency  
150 mi.  
500 mi.  
1000 mi.  
2000 mi.  
Pre-  
(240 km) (800 km) (1600 km) (3200 km)  
Season  
FUEL MANAGEMENT  
Pilot Air Screws  
Carburetor (synchronize)  
Idle RPM  
--  
52  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
--  
Throttle Lever  
39,55  
--  
I
I
I
Oil Pump Lever  
(synchronize)  
Throttle Cable  
Choke Cable  
Vent Lines  
66  
66  
--  
L
L
I
L
L
I
L
L
I
I
I
Throttle Position Sensor  
Choke  
--  
I
I
I
66  
73  
73  
73  
73  
N/A  
--  
I
I
I
Fuel Filter  
R
I
R
I
Fuel Lines  
I
I
I
Oil Filter  
R
I
R
I
Oil Lines  
I
I
I
Oil Change  
Air Box  
R
I
R
I
I
I
Drain and Water Traps  
71  
I
I
ELECTRICAL  
Auxiliary Shut-Off Switch  
Throttle Safety Switch  
Ignition Switch  
Taillight  
44  
39,54  
44  
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
I
I
I
I
I
44  
Brakelight  
44  
Headlight  
44  
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)  
C - Clean  
R - Replace  
L - Lubricate  
62  
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MAINTENANCE  
Periodic Maintenance Interval Table  
Item  
See  
Page  
Frequency  
150 mi.  
500 mi.  
1000 mi.  
2000 mi.  
Pre-  
(240 km) (800 km) (1600 km) (3200 km)  
Season  
CHASSIS  
Ski Toe Alignment  
--  
--  
I
I
I
I
I
I
Suspension Mounting  
Bolts  
I
I
Steering Fasteners  
Rear Suspension  
--  
--  
I
I
I
I
I
I
I
I
C
I
Fasteners  
Suspension Shock Oil  
Cooling Fins and Shroud  
Drive Shaft Bearings  
Jackshaft Bearings  
Skags (Wear Bars)  
Ski Saddle/Spindle Bolts  
Ski Pivots  
--  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
--  
I
66  
66  
93  
--  
L
L
I
L
L
I
L
L
I
I
I
I
I
I
64  
64  
64  
64  
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
Ski Spindle  
Steering Arm(s)  
Upper/ Lower Steering  
Post Support Bracket  
Hood Straps  
43  
95  
89  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Battery Fluid Level  
Rear Wheel Idler Bolts  
and Nuts  
Rear Suspension Pivot  
Shafts  
65  
L
I
L
I
L
Camber Alignment  
Radius Rod Bushings  
Handlebar Centering  
Track Alignment  
Track Tension  
--  
--  
I
I
I
I
I
I
I
I
I
--  
90  
88  
--  
I
I
I
I
I
I
I
I
I
I
I
I
Front Limiter Strap  
Rail Slide Condition  
Chaincase Oil  
94  
N/A  
67  
I
I
I
I
I
I
R
R
Gearcase Oil  
63  
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MAINTENANCE  
Lubrication  
Suspension and Steering  
Lubricate the suspension and steering components with Polaris Pre-  
mium All-Season Grease at 500 miles (800 km) and annually or every  
1000 miles (1600 km) thereafter. A grease gun kit, complete with grease  
and adaptors, is available to lubricate all fittings on Polaris snowmo-  
biles. See page 103 for the part numbers of Polaris products.  
The illustration shows the lubrication points of suspension and steering  
components. A + indicates a grease point or fitting.  
• Grease the left and right spindles. Raise the front end of the snowmo-  
bile to permit better grease entry into the spindle area.  
• Lubricate both of the front ski pivots at the fittings as shown.  
• Grease the jackshaft and driveshaft clutch side bearings.  
• Use an aerosol lubricant on the steering post support bracket.  
• Grease the steering post lower pivot.  
• Grease the rear suspension pivot shafts (raise the rear of unit).  
+
+
+
+
+
+
64  
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MAINTENANCE  
Lubrication  
Rear Suspension  
WideTrak Rear Suspension  
+
+
+
+
+
65  
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MAINTENANCE  
Lubrication  
Jackshaft Bearing  
The jackshaft bearing on your model may be equipped with a grease fit-  
ting, but this component is greased for life at the factory. Additional  
lubrication is not required.  
Driveshaft Bearing  
Inject grease into the fitting on the  
+
speedometer drive adaptor until  
grease purges from inside or outside  
the bearing seal (approximately two  
pumps).  
Throttle Cable  
Lubricate the throttle cable lightly  
with grease or oil. With the engine  
off, turn the handlebars to the left  
and lubricate liberally as shown.  
+
Choke and Cable  
Lubricate the choke slide and cables  
+
lightly with oil or grease. Before  
turning the engine off, operate the  
choke intermittently to draw mois-  
ture out of the choke plunger area  
and reduce the possibility of the  
choke becoming frozen.  
Coupler Greasing  
+
Grease the couplers on the drive-  
shaft and jackshaft.  
+
66  
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MAINTENANCE  
Lubrication  
n Gearcase Oil Level  
Check the gearcase oil level at the  
intervals outlined in the maintenance  
charts beginning on page 63. Change  
the gearcase oil after the first 500  
miles (800 km), then every 1000 miles  
(1600 km) or seasonally.  
1
To check the oil level, place the snow-  
mobile on a level surface. The oil  
level should be between the “safe”  
marks on the dipstick (1). See your  
Polaris dealer for the recommended  
oil for your snowmobile. Do not over-  
fill.  
Clean the magnetic plug (2) every 500  
miles (800 km) and whenever check-  
ing or changing lubricant.  
NOTICE: Mixing brands or using non-  
recommended lubricants could  
result in excessive wear to  
2
chain, sprockets and bearings. Always use Polaris-recommended  
products for your vehicle.  
67  
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MAINTENANCE  
Spark Plugs  
It’s very important to use the correct spark plug for your snowmobile. A  
spark plug with a heat range too high will cause engine damage. A spark  
plug with a heat range too low will cause excessive fouling and engine  
malfunctioning.  
In selecting a spark plug heat range for production, a manufacturer  
assumes that the engine will be operated under extreme heavy duty con-  
ditions and selects a spark plug that will protect the engine from internal  
damage if the purchaser actually does operate the engine in this manner.  
This selection could cause the customer who normally operates the  
engine under medium or light duty to have spark plug failure.  
NOTICE: A spark plug with a heat range too high will always cause engine  
damage if the engine is operated in conditions more severe than  
intended for that plug. Always use the spark plugs recommended for  
your snowmobile. Refer to your Owner’s Manual Supplement.  
A new engine can cause temporary spark plug fouling due to the preser-  
vative added during the assembly process. Avoid prolonged idle speeds,  
which cause plug fouling and carbonization.  
• Use recommended spark plugs with the proper gap. Refer to your  
Owner’s Manual Supplement.  
• Spark plug torque is 18-22 ft. lbs. (24.4-29.8 Nm).  
• Always carry spare spark plugs in case of an emergency.  
NOTICE: Using non-recommended spark plugs can result in serious engine  
damage. Always use Polaris-recommended spark plugs.  
68  
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MAINTENANCE  
Spark Plugs  
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.  
CAUTION! A hot exhaust system and engine can cause burns. Wear  
protective gloves when removing a spark plug for inspection.  
Tip: 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 carburetor(s). Refer to your Owner’s Manual Sup-  
plement.  
Normal Plug  
The normal insulator tip is gray, tan or light brown. There will be few  
combustion deposits. The electrodes are not burned or eroded. This indi-  
cates the proper type and heat range for the engine and the service.  
The tip should not be white. A white insulator tip indicates overheating,  
caused by use of an improper spark plug or incorrect carburetion adjust-  
ments.  
Wet Fouled Plug  
The wet fouled insulator tip is black. A damp oil film covers the firing  
end. There may be a carbon layer over the entire nose. Generally, the  
electrodes are not worn. General causes of fouling are excessive oil, use  
of non-recommended injection oil, improper use of the choke, or incor-  
rect carburetion adjustments.  
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 it.  
3. Reverse the procedure for spark plug installation. Torque to 18-22  
ft. lbs. (24.4-29.8 Nm).  
4. Reinstall the spark plug cap.  
69  
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MAINTENANCE  
Intake Filter  
The intake foam filter and screen limits snow ingestion into the intake  
system. When operating in loose powder snow, check the top of the  
foam filter and screen periodically to remove any accumulation of snow.  
NOTICE: Operating the snowmobile with the intake filters removed may cause  
carburetor icing. The result will be poor fuel economy or carburetor  
malfunction. Always reinstall the intake filters before operating the  
snowmobile.  
These illustrations are general representations.Your model may differ.  
Foam Filter  
Intake  
Foam Filter and Screen  
Air Intake Box  
70  
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MAINTENANCE  
Carburetor  
Water/Sediment Trap Service  
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 ventilated area away from anything that may cause the fuel to ignite, such  
as open flames, sparks, heaters, trouble lights, cigarettes, etc. Review the  
gasoline warnings found on page 49.  
Plug Cleaning Procedure  
1. Turn the fuel valve off.  
Clamp  
2. Position a container or shop towels to  
catch the contaminated gasoline.  
3. Slide the clamp away from the drain  
plug and remove the drain plug from the  
sediment tube.  
4. Wipe residue from the plug and reinstall  
it. Reposition and tighten the clamps.  
Continue until all the traps have been  
emptied.  
Drain  
Plug  
71  
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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.  
NOTICE: 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  
72  
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MAINTENANCE  
Fuel Filter/Fuel Lines  
The fuel filter is located inside the fuel tank. This component requires  
no maintenance.  
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.  
NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel  
lines may cause damage to the lines. If a fuel line has been damaged  
or kinked, replace it promptly.  
Oil Filter  
The oil filter is located at the side of  
the oil tank. Have your dealer change  
the oil filter and bleed the system annu-  
ally or every 1000 miles (1600 km).  
Tip: The direction of the arrows indicates  
the direction of flow through the filter.  
73  
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MAINTENANCE  
Exhaust System  
Check the exhaust system for wear or damage at approximately 1000  
miles (1600 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.  
CAUTION! 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.  
Drive Chain Tension  
Your WideTrak is equipped with an automatic chain tensioner. No main-  
tenance or inspection should be necessary.  
74  
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MAINTENANCE  
Brakes  
n Hydraulic Brake Inspection  
Inspect the brake lever reserve before each use of the snowmobile. See  
page 40.  
Brake pads must be replaced when the brake pad material becomes thin-  
ner than the backing plate, approximately 1/16 inch (1.5 mm). 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 1/16 inch/1.5 mm).  
Brake Components  
1. Brake Caliper  
2
2. Chaincase  
4
3. Brake Disc  
3
4. Backing Plate  
5. Brake Pad Material  
(replace when thick-  
ness is less than 1/16  
inch/1.5 mm)  
1
5
75  
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MAINTENANCE  
Brakes  
Brake Fluid  
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  
rapidly absorbs moisture from the air. The moisture causes the boiling  
temperature of the brake fluid to drop, which can lead to early brake fade and  
the possibility of accident or severe injury.  
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.  
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.  
We recommend the use of Polaris DOT 4 high temperature brake fluid.  
See page 103 for the part numbers of Polaris products.  
NOTICE: Brake fluid will damage labels, paint and some plastics. Always wipe  
up spills immediately.  
Replace brake fluid at least every two years.  
76  
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MAINTENANCE  
Brakes  
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 brake master cylinder reservoir cover and gasket.  
2. Fill the master cylinder reservoir to between the MIN and MAX  
marks or 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir  
opening. 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.  
8. Reinstall the gasket and cover.  
77  
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MAINTENANCE  
Lights  
Headlight Adjustment  
The headlight may be adjusted for vertical aim using the following pro-  
cedure:  
1. Place the snowmobile on a level surface with the headlight approxi-  
mately 25 feet (7.6 m) from a wall.  
2. Measure the distance from the floor to the center of the headlight  
and make a mark on the wall.  
3. Start the engine and turn the headlight switch to high beam.  
4. Observe the headlight aim. The most intense part of the headlight  
beam should be aimed two (2) inches (5.1 cm) below the mark  
placed on the wall in step 4.  
Tip: Rider weight must be included on the seat.  
5. Turn the adjustment nut, located inside the hood, just below the  
headlamp opening. Turn the knob in or out as needed for proper  
aim.  
25 ft. (7.6 m)  
Lamp Center Height  
2 in. (5.1 cm)  
Adjustment  
Nut  
78  
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MAINTENANCE  
Lights  
Avoid touching 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 fin-  
gers do touch the bulb, clean it with an alcohol-moistened towel.  
Headlight Bulb Replacement  
1. Pinch the ends of the spring (1)  
together and lift until it releases  
from the spring retainer.  
3
2. Lift the spring carefully around  
the wire harness (2) and flip it to  
the outside of the housing.  
2
3. With the wire harness attached  
to the bulb (3), withdraw the  
bulb from the housing.  
1
4. Grasp the bulb by its metal base  
and carefully separate the bulb from the harness.  
5. Hold the new bulb by its metal base and install it into the wire har-  
ness.  
6. Insert the bulb into the housing. Carefully flip the spring back into  
the housing, placing it around the wire harness.  
7. Squeeze the spring together until it's over the spring retainer and  
release.  
8. Verify headlight aim. See page 78.  
Taillight/Brakelight Replacement  
1. Remove the screws (1) securing the  
taillight housing (2).  
2. Remove and replace the bulb (3).  
3. Reassemble all components.  
3
1
2
79  
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MAINTENANCE  
Clutch System  
Periodically inspect the clutch sheaves for damage, wear, or belt resi-  
due. To maintain optimum performance, clean with non-oil based clean-  
ers such as isopropyl alcohol.  
NOTICE: 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 snowmobile 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.  
NOTICE: 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. Please see your Polaris dealer if you experience a decrease in  
performance.  
Clutch Center Distance  
See your Owner's Manual Supplement for recommended center distance  
for your machine. If adjustment is necessary, see your dealer.  
80  
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MAINTENANCE  
Clutch System  
n Drive Belt Condition  
Belt width and length must match the center distance of the clutches and  
sheave width of the drive clutch. For this reason, Polaris recommends  
that only O.E.M. belts be used. Other belts may match the dimensions,  
but can drastically change the shift pattern, resulting in poor perfor-  
mance. See Belt Troubleshooting on page 105.  
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.  
Tip: A worn belt will continue to function, but will not deliver maximum perfor-  
mance. Always carry a spare belt in case of an emergency.  
For improved drive-away during extremely cold temperatures, remove  
the belt and warm it to room temperature. Reinstall it before starting the  
snowmobile.  
81  
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MAINTENANCE  
Clutch System  
Drive Belt Removal  
1. Stop the engine after operating in  
a forward motion.  
NOTICE: Do not attempt to remove the  
drive belt after operating in  
reverse. The snowmobile must  
be stopped after forward motion  
to prevent damage to compo-  
nents during belt removal.  
2. Turn the ignition key off. Wait for  
the engine to stop completely.  
3. Lock the parking brake (if  
equipped).  
4. Open the hood.  
5. Remove the clutch guard retaining pin and open the clutch guard.  
6. Rotate the driven clutch counterclockwise 1/4 turn by hand to  
ensure forward engagement before attempting to remove the belt.  
7. Firmly grasp the belt midway between the clutches and pull upward  
and rearward to remove. See illustration.  
82  
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MAINTENANCE  
Clutch System  
Drive Belt Installation  
1. Drop the drive belt over the  
drive clutch and pull back  
the slack.  
Tip: To ensure satisfactory belt life,  
install belts so they operate in  
the same direction of rotation  
by positioning the identification  
numbers so that you can read  
them. If required, separate the  
sheaves as outlined in the belt  
removal procedures.  
2. Turn the driven clutch  
moveable sheave clockwise while pushing inward and forcing the  
belt down between the sheaves.  
3. Hold the belt down between  
the sheaves and roll the bot-  
tom portion over the outer  
clutch sheave. Work the belt  
to the outer edge of the  
sheave.  
4. Close the clutch guard and  
reinstall the retaining pin.  
5. Close and secure the hood  
and release the parking  
brake.  
83  
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MAINTENANCE  
Clutch System  
n Drive Belt Deflection  
1
Measure belt deflection with  
both clutches at rest and in their  
full neutral position.  
2
Place a straight edge on the belt  
(1) and apply downward pres-  
sure while measuring at point 2.  
This measurement should be 1  
1/4 inches (32 mm).  
Drive Belt Adjustment  
Belt deflection should be adjusted without removing the clutch from the  
jackshaft.  
1. Loosen the 7/16-inch jam nut on the belt width adjuster.  
2. Using a 1/8-inch Allen wrench, adjust the threaded set screw as  
needed.  
Tip: 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  
.010-.030 in.  
(.25-.75 mm)  
clearance. With clutches in  
proper alignment, the torque stop  
clearance should be .010-.030  
inch (.25-.75 mm) from the  
engine case.  
Adjust if necessary, and lock the  
jam nut.  
84  
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MAINTENANCE  
Tool Kit  
A tool kit is included with each snowmobile for emergency and routine  
maintenance. Always keep the tool kit with the snowmobile.  
Chain Tension  
Maintain the proper chain tension as outlined on page 74.  
Fall Tune-Up  
For maximum performance, arrange for a fall service tune-up with your  
Polaris dealer.  
85  
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MAINTENANCE  
Track  
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  
snowmobile off the ground.  
+
2. Rotate the track by hand to  
check for possible damage.  
3. Carefully examine the track  
along the entire length of  
each rod (+). Bend the  
track to check for break-  
age.  
4. Replace the track if any rod  
damage is found.  
86  
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MAINTENANCE  
Track  
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 periods on ice and other surfaces that have little or no snow for  
lubrication.  
The slide rail requires adequate snow cover for sufficient lubrication.  
Excessive wear indicates insufficient lubrication. A new rail slide can  
cause faster heat build-up in limited lubrication, resulting in excessive  
wear.  
Tip: If excessive rail slide wear occurs due to poor snow conditions, additional  
wheel kits are available. See your dealer for more information.  
Tip: Track damage or failure caused by operation on ice or under other poor  
lubrication conditions will void the track warranty.  
87  
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MAINTENANCE  
Track  
WARNING  
Moving parts can cut and crush body parts. When performing the checks and  
adjustments recommended on the following pages, stay clear of all moving  
parts. Never perform track measurement or adjustments with the engine run-  
ning.  
Track Tension  
Track adjustment is critical for proper handling. Always maintain cor-  
rect tension and alignment. Tension adjustments should be made only  
after the track is warmed up and limber.  
WARNING! Improper track tension can cause serious damage to the  
snowmobile, which can result in loss of vehicle control and serious injury or  
death. Always maintain the track tension as specified.  
1. Turn the engine off.  
2. Lift the rear of the snowmobile and safely support it off the ground.  
3. Place the recommended weight or downward pressure on the track  
at the location specified (see chart and illustration).  
Weight  
Measurement  
Location  
Measurement  
10 lbs. (4.54 kg)  
16 inches (40 cm) ahead of  
forward idler wheel shaft bolt  
3/4-1 inch (2-2.5 cm)  
4. Measure at the point where the weight is hanging.  
5. Check for specified slack between the wear surface of the track clip  
and the plastic rail slide.  
88  
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MAINTENANCE  
Track  
Track Tension  
Locknut  
Slack Measurement  
Adjusting  
Screw  
Idler  
Shaft  
Bolt  
S
Track  
10 lbs. (4.54 kg)  
16 in. (40 cm)  
If the track needs adjustment:  
6. Loosen the rear idler shaft bolt.  
7. Loosen the locknuts.  
8. Tighten or loosen the track adjusting screws as necessary to provide  
equal adjustment on both sides of the track.  
9. Repeat the measurement on the other side of the track.  
Tip: Check more frequently when snowmobile is new.  
10. Start the engine and slowly rotate the track at least five revolutions.  
Let the track come to a stop (do not apply brakes).  
11. Check track alignment (see page 90) and adjust as necessary.  
12. Tighten the locknuts.  
13. Tighten the idler shaft bolts. Torque to 35 ft. lbs. (47.5 Nm).  
89  
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MAINTENANCE  
Track  
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  
snowmobile 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).  
Rails  
3. Inspect track alignment by looking through the track window to  
make sure the rails are evenly spaced on each side. If the track runs  
to the left, loosen the left locknut and tighten the left adjusting bolt.  
If the track runs to the right, loosen the right locknut and tighten the  
right adjusting bolt.  
4. After adjustments are complete, tighten locknuts and torque idler  
shaft bolts to 35 ft. lbs. (47.5 Nm).  
5. Repeat steps 2 and 3 to verify proper alignment.  
90  
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MAINTENANCE  
Steering System  
Steering Inspection  
Each week, or before a long ride, check fasteners and tighten if neces-  
sary. Specific fasteners that should be checked are marked with a + in  
the illustration.  
+
+
+
+
+
+
91  
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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  
alignment 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 1/8-1/4 inch (3-6 mm) greater than  
at point Y.  
Tip: If the skis are misaligned, we recommend that your dealer correct the align-  
ment, since camber adjustment may also be affected.  
X
10 in. (25.4 cm)  
10 in. (25.4 cm)  
Y
92  
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MAINTENANCE  
Steering System  
n Ski Skags  
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 con-  
trol while turning on hard-packed snow or ice.  
WARNING! Worn skis and/or skags will adversely affect handling. Loss of  
vehicle control may result, causing serious injury or death.  
Check skags weekly to maintain positive steering characteristics. Skags  
must be replaced when worn to half their original diameter. Carbide  
skags must be replaced if any abnormal wear or chipping is found.  
Skag Replacement  
1. Raise and support the front of the snowmobile so the skis are  
approximately 6I (15.2 cm) from the ground.  
2. Remove the attaching hardware and pry the skag downward.  
3. Remove the rear end of the skag.  
4. Remove the front end of the skag.  
5. Reverse the steps to install a skag.  
93  
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MAINTENANCE  
Suspension Maintenance  
n Rail Slide Wear  
Minimum  
Thickness  
For ease of inspection, all  
Polaris rail slides have a  
wear limit indicator groove  
to indicate the minimum per-  
missible slide thickness.  
Replace the rail slides if they  
are worn to the top of the  
groove at any point along  
their length. Failure to do so  
may result in permanent  
damage to the track or rails.  
Replace when  
worn to top of  
groove  
Suspension Inspections  
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 89.  
n Check rear idler adjusting bolt locknuts for tightness.  
n Check front torque arm limiter strap condition.  
n Check rail slide condition.  
n Check track tension. See page 88.  
n Lubricate/grease all suspension components. See page 64.  
n Check ski runner/skag condition. See page 93.  
n Check ski spindle bolts for tightness.  
n Check tie rod end nuts for tightness.  
94  
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MAINTENANCE  
Battery  
WARNING  
Battery electrolyte is poisonous. It contains acid! Serious burns can result from  
contact with the skin, eyes, or clothing. If contact occurs, seek immediate medi-  
cal attention.  
KEEP OUT OF REACH OF CHILDREN.  
EXTERNAL: Flush with water.  
INTERNAL: Drink large quantities of water or milk. Call physician immediately.  
EYES: Flush with water for 15 minutes and get prompt medical attention.  
Batteries produce explosive gases. Keep sparks, open flames, cigarettes, etc.  
away. Ventilate when charging or using in closed space. Always shield eyes  
when working near batteries.  
Battery Fluid  
A poorly maintained battery will  
Upper Mark  
deteriorate rapidly. Check the battery  
fluid level often. The fluid level  
should be kept between the upper and  
lower level marks.  
NOTICE: Tap water contains minerals  
Lower  
Mark  
that will damage a battery and  
shorten its life. Use only  
distilled water to refill your  
battery. Never allow cleaning  
solution or tap water to enter  
the battery.  
95  
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MAINTENANCE  
Battery  
Battery Connections  
Keep battery terminals and connections free of corrosion. When clean-  
ing is necessary, remove the corrosion with a stiff wire brush. Wash ter-  
minals and connections with a solution of one tablespoon baking soda  
and one cup water. Rinse well with tap water and dry with clean shop  
towels. Coat the terminals with dielectric grease or petroleum jelly.  
Battery Removal  
WARNING! Improperly connecting or disconnecting battery cables can result in  
an explosion and cause serious injury or death. When removing the battery,  
always disconnect the negative (black) cable first. When reinstalling the battery,  
always connect the negative (black) cable last.  
1. Disconnect the battery hold-down straps.  
2. Remove the battery vent tube from battery.  
3. Disconnect the black (negative) battery cable first.  
4. Disconnect the red (positive) battery cable last.  
5. Carefully lift the battery out of the snowmobile. Do not tip it side-  
ways or spill electrolyte.  
NOTICE: If electrolyte spills, immediately wash it off with a solution of one  
tablespoon baking soda and one cup water to prevent damage to the  
vehicle.  
96  
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MAINTENANCE  
Battery  
Battery Installation  
WARNING! Battery electrolyte contains acid. Avoid skin contact with electrolyte  
as severe burns may result.  
Using a new battery that has not been fully charged can damage the bat-  
tery and result in a shorter life. It can also hinder vehicle performance.  
1. Ensure that the battery is fully charged.  
2. Place the battery in the battery holder. Attach the hold down strap.  
3. Install the battery vent tube. The vent tube must be free of obstruc-  
tions and securely installed. Route the vent tube properly to prevent  
kinks and to allow for proper drainage.  
WARNING! Battery gases could accumulate in an improperly installed vent tube  
and cause an explosion, resulting in serious injury or death. Always ensure that  
the vent tube is free of obstructions and is securely installed as recommended.  
Whenever removing or installing the battery, disconnect the negative (black)  
cable first and reinstall the negative cable last to avoid the possibility of  
explosion.  
4. Coat the terminals with dielectric grease or petroleum jelly.  
5. Connect and tighten the red (positive) cable first.  
6. Connect and tighten the black (negative) cable last.  
7. Verify that cables and vent tube are properly routed.  
97  
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MAINTENANCE  
Battery  
Battery Storage  
When your snowmobile is placed in storage for one month or more (in  
summer or in winter):  
• Remove the battery.  
• Charge it to the proper level.  
• Store it in a cool dry place.  
• Check and/or charge monthly.  
• Have the battery tested and recharged before reinstalling it in the  
vehicle.  
If a battery with a low charge freezes, the cells could be damaged.  
Always maintain a full charge on a stored battery. See the table below.  
Charge condition  
Will freeze at:  
100%  
75%  
50%  
25%  
0%  
-75_ F (-59_ C)  
-24_ F (-31_ C)  
0_ F (-18_ C)  
+13_ F (-11_ C)  
+18_ F (-8_ C)  
98  
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MAINTENANCE  
Daily Storage  
At the end of each ride, park the snowmobile on a level surface and sup-  
port it at the rear with an appropriate track stand. The track should be  
suspended approximately 4 inches (10 cm) off the ground.  
Remove the key and cover the snowmobile.  
Tip: Polaris has accessory covers and track stands available to fit all models.  
See your dealer for more information.  
99  
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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.  
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 surfaces  
before beginning preservation with waxes and rust inhibitors (grease, oil  
or paint).  
The snowmobile should be stored in a dry garage or shed, out of direct  
sunlight, and covered with a fabric snowmobile cover. Plastic tarp may  
cause condensation to form and damage snowmobile components.  
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 snowmobile is stored for a period of more than 60 days,  
the engine must be fogged with fogging oil. Follow the engine fogging  
instructions provided on the can. See page 101.  
Always add Premium Carbon Clean or a fuel conditioner/stabilizer to  
the fuel tank. Follow the instructions on the can, running the engine for  
five minutes to get additives through the entire fuel system. Top off with  
fresh fuel.  
Tip: For easier starting after extended storage, add lubricant to the fuel in the  
tank at a 40:1 ratio and run the engine for three to five minutes before stor-  
age. This will lubricate the fuel pump diaphragm to keep it flexible and help  
prevent loss of prime.  
If stabilizer is not used, drain the carburetors by removing the water trap  
drain plugs (see page 71). Catch fuel in a container or shop cloth. Rein-  
stall plugs securely. Observe all fire safety rules when draining carbure-  
tors. See gasoline warnings on page 49.  
Tip: Jet restriction caused by improper storage can cause lean conditions and  
very poor slow speed driving quality.  
100  
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MAINTENANCE  
Extended Storage  
Engine and Carburetor Protection  
Using a fuel stabilizer and topping off the fuel tank eliminates the need  
to drain the fuel system. If you prefer to drain the fuel tank, use the fol-  
lowing procedure:  
1. Transfer unused fuel from the fuel tank to an approved fuel con-  
tainer using a siphon pump. Do not re-use fuel after storage.  
2. Securely support the front of the snowmobile with a jack stand so  
the snowmobile is elevated and the engine is tilted rearward.  
3. Remove the spark plug(s).  
4. Rotate the engine slowly, watching the piston until it’s at bottom  
dead center (BDC), the lowest position in the cylinder. On twin cyl-  
inder models, the opposite piston will be up.  
5. Pour approximately two ounces of Polaris injector oil into the spark  
plug hole.  
6. Wait one to two minutes and perform steps 3 to 5 on remaining cyl-  
inders.  
7. Replace the spark plugs and lower the snowmobile to the floor.  
Controls and Linkage  
All bushings, spindle shafts, tie rod ends, and cables should receive a  
light coat of oil or grease.  
Bearings  
Grease the drive shaft clutch side bearing with Polaris Premium All-  
Season Grease or a similar high quality grease to prevent corrosion. See  
page 103 for part numbers.  
Clutch and Drive System  
Remove the drive belt and store in a cool dry location. Lubricate the  
sheave faces of the drive and driven clutches with a light coat of oil or  
Polaris Cable Lubricant. See page 103 for the part numbers of Polaris  
products. Do not lubricate clutch components, except the driven clutch  
shaft bushing as outlined in the Master Repair Manual. See your dealer.  
101  
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MAINTENANCE  
Extended Storage  
Electrical Connections  
Separate electrical connector blocks and clean corrosive build-up from  
connectors. Lubricate or pack connector blocks with dielectric grease  
and re-connect. See page 103 for the part numbers of Polaris products.  
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.  
Battery  
Always prepare and maintain the battery as outlined on page 95.  
Track and Suspension  
Moderate track tension should be maintained during summer storage.  
The snowmobile should be supported off the ground to allow the track  
to hang freely.  
Transporting the Snowmobile  
Whenever the snowmobile is transported:  
1. Turn the fuel valve off.  
2. Be 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.  
102  
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POLARIS PRODUCTS  
Description  
Part No.  
Engine Lubricants  
2870791  
2871098  
2871097  
2871240  
2871721  
2871722  
2872347  
Fogging Oil (12 oz. Aerosol)  
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.)  
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 (Nyogel™)  
2871312  
2871322  
2871423  
2871329  
Additives / Miscellaneous  
2871326  
2870652  
2872189  
2872893  
2870505  
2872889  
2872890  
Carbon Clean Plus (12 oz.)  
Fuel Stabilizer (16 oz.)  
DOT4 Brake Fluid (12 oz.)  
Engine Degreaser (12 oz.)  
Isopropyl  
Brake and Clutch Cleaner  
Carb and Throttle Body Cleaner  
103  
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TROUBLESHOOTING  
Suspension Troubleshooting  
Problem  
Solution (perform only one change at a time)  
Rear suspension bot- • Verify sag dimension (see page 89). Adjust torsion spring  
toms too easily  
blocks or install optional torsion springs to achieve correct  
sag dimensions.  
Rear suspension  
rides too stiff  
• Check for binding suspension components and grease all  
pivot points.  
• Verify sag dimension (see page 89). Adjust torsion spring  
blocks or install optional torsion springs to achieve correct  
sag dimensions.  
• Decrease shock compression damping (see page 34).  
Too much weight  
transfer when climb-  
ing  
• Verify sag dimension (see page 89). Adjust torsion spring  
blocks or install optional torsion springs to achieve correct  
sag dimensions.  
Too little weight  
transfer when climb-  
ing  
• Verify sag dimension (see page 89). Adjust torsion spring  
blocks or install optional torsion springs to achieve correct  
sag dimensions.  
Front end pushes  
• Check for worn skags  
• Check for binding front suspension shafts and steering com-  
ponents, grease all pivot points (elevate front of machine).  
• Verify sag dimension (see page 89). Adjust torsion spring  
blocks or install optional torsion springs to achieve correct  
sag dimensions.  
• Increase IFS preload (see page 32).  
Steering is heavy  
• Check skags and skis for damage.  
• Check for binding front suspension shafts and steering com-  
ponents, grease all pivot points (elevate front of machine).  
• Verify sag dimension (see page 89). Adjust torsion spring  
blocks or install optional torsion springs to achieve correct  
sag dimensions.  
• Decrease IFS preload (see page 32).  
Snowmobile darts  
from side to side  
• Ensure skis are properly aligned (see page 92).  
• Check for binding front suspension shafts and steering com-  
ponents, grease all pivot points (elevate front of machine).  
• Ensure skags are straight on skis.  
104  
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TROUBLESHOOTING  
Belt Wear/Burn Troubleshooting  
Belt Wear/Burn Diagnosis  
Causes  
Solutions  
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 snowmobile in extremely cold weather and warm it  
up. Break snowmobile 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. Remove windage plates from the  
clutch. Reduce RPM. Avoid riding in high ambient  
temperatures.  
Ice and snow build-up  
between track and  
tunnel  
Warm the engine at least five minutes. Take the drive belt  
off the snowmobile in extremely cold weather and warm it  
up. Break snowmobile loose from the snow.  
Poor engine  
performance  
Check for carb and choke synchronization, fouled plugs,  
debris in the carbs, and water, ice or dirt in the gas tank or  
fuel line.  
Loading snowmobiles  
onto trailers  
Skis may gouge into trailers and prevent the drive train  
from spinning properly. Use enough speed to drive the  
snowmobile completely onto the trailer. Push and pull it to  
finish loading if necessary.  
Clutch malfunction  
Inspect clutch components. See your dealer.  
Use fast, aggressive throttle to engage clutch.  
Slow, easy clutch  
engagement  
105  
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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  
operating RPM  
during acceler-  
ation or load  
variations  
Drive clutch binding  
• Disassemble drive clutch to inspect shift  
weights for wear and free operation.  
SEE YOUR DEALER.  
• Clean and polish stationary shaft hub.  
Driven clutch  
malfunction  
• Replace ramp buttons and rollers. SEE  
YOUR DEALER.  
• Inspect movable sheaves for excessive  
bushing clearance and replace if neces-  
sary. SEE YOUR DEALER.  
Harsh drive  
Drive belt worn or too • Replace drive belt.  
clutch engage- narrow  
ment  
Excessive belt/sheave  
• SEE YOUR DEALER.  
clearance  
Drive belt turns Wrong belt for applica- • Replace drive belt.  
over  
tion  
Clutch alignment out  
of spec  
• Adjust alignment offset.  
Engine mount broken  
or loose  
• Inspect and adjust or replace. SEE  
YOUR DEALER.  
Snowmobile  
fails to move  
Clutch jammed  
• Belt twisted, spring broken, weights  
stuck, lubricated. SEE YOUR  
DEALER.  
Track jammed  
• Foreign object caught or rail slide  
melted to track clips due to lack of  
lubrication.  
• Machine may be frozen to ground.  
Track may be iced up.  
Chaincase sprocket or  
chain jammed or bro-  
ken  
• Chain is loose or broken, chain tight-  
ener is loose. SEE YOUR DEALER.  
106  
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TROUBLESHOOTING  
Engine Troubleshooting  
Problem  
Probable Cause Solution  
Noise in drive  
system  
Broken drive clutch  
components  
• SEE YOUR DEALER.  
Bearing failure/ chain- • SEE YOUR DEALER.  
case, jackshaft, or front  
drive shaft  
Drive belt surface flat  
spots  
• Inspect and replace if necessary.  
Drive chain loose or  
worn, sprocket teeth  
broken  
• Inspect and adjust or replace.  
Poor low RPM Worn drive belt  
performance  
• Inspect and replace if necessary.  
• SEE YOUR DEALER.  
Excessive belt/sheave  
clearance  
Loose torque stop  
Sticky clutch  
• Inspect and adjust.  
• SEE YOUR DEALER.  
• SEE YOUR DEALER.  
Engine doesn’t Wire connections  
start (electric  
start models)  
Engine doesn’t Seized engine  
turn  
• SEE YOUR DEALER. Seizure is a  
result of poor lubrication, inadequate  
fuel supply, broken parts, or improper  
cooling.  
Hydrostatic lock  
• Fuel may have entered crankcase  
while vehicle was standing or being  
transported. SEE YOUR DEALER to  
correct cause. Drain plug(s) are  
located on lower crankcase for emer-  
gency draining.  
107  
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TROUBLESHOOTING  
Engine Troubleshooting  
Problem  
Probable Cause  
Solution  
Engine turns  
but fails to start  
Faulty ignition  
• Remove spark plug(s) and replace  
with new plug(s). If engine still fails  
to start, check for spark; if no spark  
SEE YOUR DEALER.  
No fuel to engine  
• Make sure the fuel valve is ON.  
Check tank level and fill up with cor-  
rect fuel.  
• Ice in fuel line, filter, or pump. On the  
standard Polaris carburetor, the choke  
will not function with the throttle  
depressed. See second item under  
“Probable Cause” of “Engine contin-  
ually backfires”.  
Flooded engine (normal • Hold throttle open, crank engine sev-  
situation caused by too  
much choking)  
eral times (may be necessary to  
change plug(s), however, the plug(s)  
may operate satisfactorily when  
dried).  
Poor engine compression • Running too lean a mixture (too small  
a main jet will cause seizure resulting  
in loss of power). SEE YOUR  
DEALER. This indicates a major  
engine problem that must be repaired  
before engine is run.  
Engine lacks  
power  
Fouled or defective  
spark plug  
• Change and test operation.  
Fuel filter (loss of high  
RPM power)  
• Check fuel filter flow. Disconnect  
hose and drain about 1/2 cup. Fuel  
flow should be steady and encompass  
the entire diameter of fuel line. If not,  
replace filter.  
Incorrect clutching  
• SEE YOUR DEALER.  
Carburetor and fuel  
pump  
• There’s no adjustment to change  
power output. SEE YOUR DEALER.  
Engine continu- Faulty plug(s)  
• Change plug(s)  
ally backfires  
Carburetor  
• Dirt or ice in fuel system. (Deicer  
should be added to non-ethanol fuel  
at all times for assurance against fuel  
line icing.)  
Engine requires Poor gasoline or not  
more than nor- enough fuel getting to  
• Replace with fresh winter fuel.  
mal pulls to  
start  
engine  
108  
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WARRANTY  
Service And Warranty Information  
Obtaining Service and Warranty Assistance  
Read and understand the service data and the Polaris warranty informa-  
tion contained in this manual. Contact your Polaris dealer for replace-  
ment parts, service 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  
following information:  
1. Serial number  
2. Model number  
3. Dealer name  
4. Date of purchase  
5. Details of trouble experienced  
6. Length of time and conditions of operation  
7. Previous correspondence  
Use the page 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: 1-888-704-5290  
Canada: 1-204-925-7100  
109  
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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 number 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  
110  
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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 war-  
ranty 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 set-up of your snowmobile is very important in ensuring  
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer  
set-up 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 REM-  
EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-  
ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL  
HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL  
OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF  
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLI-  
GENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-  
sion 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.  
111  
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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 transportation to  
and from the dealer is YOUR responsibility). Polaris recommends that you use your  
original selling dealer; however, you may use any Polaris Servicing Dealer to perform  
warranty service.  
Please work with your dealer to resolve any warranty issues. Your dealer will contact the  
appropriate personnel at 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.  
112  
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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.  
113  
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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.  
114  
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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, Warranty 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 109).  
115  
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WARRANTY  
U.S.A. EPA Emissions Limited Warranty  
This emissions limited warranty is in addition to the Polaris standard limited warranty  
for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this  
emissions-certified vehicle is designed, built and equipped so it conforms with applica-  
ble U.S. Environmental Protection Agency emission regulations. Polaris warrants that  
the vehicle is free from defects in materials and workmanship that would cause it to fail  
to meet these regulations.  
The warranty period for this emissions-certified vehicle starts on the date the vehicle is  
first purchased and continues for a period of 200 hours of engine operation, 4000 kilo-  
meters (2485 miles) of vehicle travel, or 30 calendar months from the date of purchase,  
whichever comes first.  
This emissions limited warranty covers components whose failure increases the vehi-  
cle’s regulated emissions, and it covers components of systems whose only purpose is to  
control emissions. Repairing or replacing other components not covered by this war-  
ranty is the responsibility of the vehicle owner. This emissions limited warranty does not  
cover components whose failure does not increase the vehicle’s regulated emissions.  
For exhaust emissions, emission-related components include any engine parts related to  
the following systems:  
•
•
Air-induction system  
Fuel system  
•
•
Ignition system  
Exhaust gas recirculation systems  
The following parts are also considered emission-related components for exhaust emis-  
sions:  
•
•
Aftertreatment devices  
Crankcase ventilation valves  
•
•
Sensors  
Electronic control units  
The following parts are considered emission-related components for evaporative emis-  
sions:  
•
•
•
•
•
•
•
•
•
Fuel Tank  
Fuel Cap  
Fuel Line  
Fuel Line Fittings  
Clamps*  
Pressure Relief Valves*  
Control Valves*  
Control Solenoids*  
Electronic Controls*  
•
•
•
•
•
•
•
•
•
Vacuum Control Diaphragms*  
Control Cables*  
Control Linkages*  
Purge Valves  
Vapor Hoses  
Liquid/Vapor Separator  
Carbon Canister  
Canister Mounting Brackets  
Carburetor Purge Port Connector  
*As related to the evaporative emission control system.  
116  
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WARRANTY  
U.S.A. EPA Emissions Limited Warranty  
The exclusive remedy for breach of this limited warranty shall be, at the exclusive  
option of Polaris, repair or replacement of any defective materials, components or prod-  
ucts. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE  
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-  
RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-  
DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY  
DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-  
RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR  
OTHERWISE.  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY  
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-  
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY  
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-  
TIES 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 if it is incon-  
sistent with the controlling state law.  
This limited warranty excludes failures not caused by a defect in material or workman-  
ship.This limited warranty does not cover damage due to accidents, abuse or improper  
handling, maintenance or use. This limited warranty also does not cover any engine that  
has been structurally altered, or when the vehicle has been used in racing competition.  
This limited warranty also does not cover physical damage, corrosion or defects caused  
by fire, explosions or other similar causes beyond the control of Polaris.  
Owners are responsible for performing the scheduled maintenance identified in the  
owner's manual. Polaris may deny warranty claims for failures that have been caused by  
the owner’s or operator’s improper maintenance or use, by accidents for which Polaris  
has no responsibility, or by acts of God.  
Any qualified repair shop or person may maintain, replace, or repair the emission con-  
trol devices or systems on your vehicle. Polaris recommends that you contact an autho-  
rized Polaris dealer to perform any service that may be necessary for your vehicle.  
Polaris also recommends that you use only Pure Polaris parts. It is a potential violation  
of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the  
effectiveness of the vehicle's emission controls. Tampering with emission controls is  
prohibited by federal law.  
If you have any questions regarding your warranty rights and responsibilities, please  
contact the Polaris Warranty Department at 1-888-704-5290.  
117  
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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)  
118  
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MAINTENANCE LOG  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
119  
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MAINTENANCE LOG  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
120  
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MAINTENANCE LOG  
DATE  
MILES  
(KM)  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
121  
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INDEX  
A
D
Accessories . . . . . . . . . . . . . . . . . . . 37  
Air Box Warning . . . . . . . . . . . . . . . 23  
Air Pollution . . . . . . . . . . . . . . . . . . . 5  
Apparel . . . . . . . . . . . . . . . . . . . . . . 11  
Avalanches. . . . . . . . . . . . . . . . . . . . 15  
Disabled Operators . . . . . . . . . . . . . . 12  
Drive Belt  
Safety. . . . . . . . . . . . . . . . . . . . . 18  
Adjustment . . . . . . . . . . . . . . . . 84  
Condition . . . . . . . . . . . . . . . . . . 81  
Deflection . . . . . . . . . . . . . . . . . 84  
Installation . . . . . . . . . . . . . . . . . 83  
Removal. . . . . . . . . . . . . . . . . . . 82  
Drive Chain Tension . . . . . . . . . . . . . 74  
Driver Awareness . . . . . . . . . . . . . . . 14  
Driving Downhill. . . . . . . . . . . . . . . . 18  
Driving on Slippery Surfaces . . . . . . 16  
Driving on Slopes . . . . . . . . . . . . . . . 17  
Driving Responsibly . . . . . . . . . . . . . 21  
B
Backrest . . . . . . . . . . . . . . . . . . . . . . 29  
Battery . . . . . . . . . . . . . . . . . . . . 95-98  
Connections . . . . . . . . . . . . . . . 96  
Fluid. . . . . . . . . . . . . . . . . . . . . 95  
Installation . . . . . . . . . . . . . . . . 97  
Removal. . . . . . . . . . . . . . . . . . 96  
Storage. . . . . . . . . . . . . . . . . . . 98  
Before Starting the Engine. . . . . . 39-43  
Brakes . . . . . . . . . . . . . . . . . . 40, 75-77  
Components. . . . . . . . . . . . . . . 75  
Fluid. . . . . . . . . . . . . . . . . . . . . 76  
Inspection. . . . . . . . . . . . . . . . . 75  
Lever Feel . . . . . . . . . . . . . . . . 40  
Lever Travel. . . . . . . . . . . . . . . 40  
System Bleeding . . . . . . . . . . . 77  
Brakelight Replacement. . . . . . . . . . 79  
Break-In Period . . . . . . . . . . . . . . . . 46  
E
Emission Control Information. . . . . . 59  
Emissions Limited Warranty. . 116-117  
Engine Break-In. . . . . . . . . . . . . . . . . 46  
Engine Care for Storage . . . . . 100-101  
Environment Preservation . . . . . . . . . . 5  
Exhaust System . . . . . . . . . . . . . . . . . 74  
F
Fuel . . . . . . . . . . . . . . . . . . . . . . . 49-50  
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 73  
Fuel Lines . . . . . . . . . . . . . . . . . . . . . 73  
Fuel Reserve . . . . . . . . . . . . . . . . . . . 50  
Fuel Safety. . . . . . . . . . . . . . . . . . . . . 49  
Fuel System Deicers . . . . . . . . . . . . . 50  
Fuel Valve . . . . . . . . . . . . . . . . . . . . . 27  
C
Carburetion . . . . . . . . . . . . . . . . . 52-53  
Carburetor . . . . . . . . . . . . . . . . . . 71-72  
Carburetor Adjustments. . . . . . . . . . 72  
Carburetor Protection (Storage) 100-101  
Carburetor Trap . . . . . . . . . . . . . . . . 71  
Cargo . . . . . . . . . . . . . . . . . . . . . . . . 12  
Cargo Rack . . . . . . . . . . . . . . . . . . . 29  
Chain Tension . . . . . . . . . . . . . . . . . 85  
Choke. . . . . . . . . . . . . . . . . . . . . . . . 45  
Cleaning the Vehicle . . . . . . . . . . . 100  
Clutch Alignment. . . . . . . . . . . . . . . 80  
Clutch Center Distance . . . . . . . . . . 80  
Clutch Cover Warning. . . . . . . . . . . 23  
Clutch Guard . . . . . . . . . . . . . . . . . . 18  
Clutch System . . . . . . . . . . . . . . . 80-84  
Clutches . . . . . . . . . . . . . . . . . . . . . . 19  
Cold Weather Drive-Away . . . . . . . 19  
G
Gearcase Oil Level . . . . . . . . . . . . . . 67  
H
Handlebar Adjustments . . . . . . . . . . . 35  
Headlight Adjustment . . . . . . . . . . . . 78  
Headlight Bulb Replacement. . . . . . . 79  
Hood Latches. . . . . . . . . . . . . . . . . . . 43  
122  
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INDEX  
I
P
Ice and Snow Build-up . . . . . . . . . . . 16  
IFS Adjustment Options . . . . . . . . . . 30  
IFS Components . . . . . . . . . . . . . . . . 30  
Intake Filter. . . . . . . . . . . . . . . . . . . . 70  
Intake Silencer . . . . . . . . . . . . . . . . . 19  
Parking Brake Lever Lock . . . . . . . . 41  
Passenger Warning . . . . . . . . . . . . . . 23  
Periodic Maintenance Table . . . . 61-63  
Polaris Products . . . . . . . . . . . . . . . 103  
Pre-Ride Checklist . . . . . . . . . . . . . . 38  
Pre-Ride Inspections. . . . . . . . . . 38-44  
J
R
Jetting Guidelines . . . . . . . . . . . . . . . 53  
Rail Slide Wear. . . . . . . . . . . . . . . . . 94  
Recoil Rope . . . . . . . . . . . . . . . . . . . 43  
Reverse Operation . . . . . . . . . . . . . . 57  
Reverse Warning . . . . . . . . . . . . . . . 24  
Reverse, Mechanical. . . . . . . . . . . . . 57  
Rider Capacity . . . . . . . . . . . . . . . . . 12  
L
Lever, Shift (Mechanical Reverse) . . 57  
Lights . . . . . . . . . . . . . . . . . . . . . 78-79  
Brakelight Replacement . . . . . . 79  
Headlight Adjustment. . . . . . . . 78  
Headlight Bulb Replacement . . 79  
Lubrication  
S
Choke and Cable. . . . . . . . . . . . 66  
Driveshaft Bearing . . . . . . . . . . 66  
Jackshaft Bearing . . . . . . . . . . . 66  
Rear Suspension . . . . . . . . . . . . 65  
Throttle Cable . . . . . . . . . . . . . . 66  
Safety . . . . . . . . . . . . . . . . . . . . . . 7-22  
Safety Labels . . . . . . . . . . . . . . . 23-25  
Seat Latches . . . . . . . . . . . . . . . . . . . 43  
Shock Components . . . . . . . . . . . . . . 31  
Shock Spring Preload . . . . . . . . . . . . 32  
Ski Alignment. . . . . . . . . . . . . . . . . . 92  
Ski Skags . . . . . . . . . . . . . . . . . . . . . 93  
Slide Rail and Track Cooling . . . . . . 47  
Snow Conditions. . . . . . . . . . . . . . . . 20  
Spark Plugs . . . . . . . . . . . . . . . . . 68-69  
Speed. . . . . . . . . . . . . . . . . . . . . . . . . 13  
Spring Settings, Rear, WideTrak . . . 34  
Springs, Front . . . . . . . . . . . . . . . . . . 32  
Starting the Engine . . . . . . . . . . . . . . 45  
Starting, Emergency . . . . . . . . . . . . . 56  
Steering Inspection . . . . . . . . . . . . . . 91  
Steering Lubrication . . . . . . . . . . . . . 64  
Steering System . . . . . . . . . . 42, 91-93  
Stop Switch. . . . . . . . . . . . . . . . . . . . 54  
Stopping, Emergency . . . . . . . . . . . . 56  
Storage, Daily . . . . . . . . . . . . . . . . . . 99  
Storage, Extended. . . . . . . . . . 100-102  
Survival Preparation . . . . . . . . . . . . . 10  
M
Maintenance Program. . . . . . . . . . . . 60  
Maneuverability . . . . . . . . . . . . . . . . 19  
N
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
O
Oil . . . . . . . . . . . . . . . . . . . . . . . . 51-52  
Oil Filter . . . . . . . . . . . . . . . . . . . . . . 73  
Oil Indicator Light . . . . . . . . . . . . . . 51  
Oil Injection System . . . . . . . . . . . . . 47  
Oil Level . . . . . . . . . . . . . . . . . . . . . . 52  
Oil Recommendations. . . . . . . . . . . . 47  
Oil, Gearcase. . . . . . . . . . . . . . . . . . . 67  
Operating in Deep Snow. . . . . . . . . . 20  
Operation Warning . . . . . . . . . . . . . . 25  
123  
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INDEX  
S
T
Suspension Adjustments, Front . . 30-32  
Suspension Adjustments, Rear . . 33-34  
Suspension Inspections . . . . . . . . . . 94  
Suspension Lubrication . . . . . . . . 64-65  
Suspension Maintenance . . . . . . . . . 94  
Suspension Performance Tips . . . . . 33  
Suspension Troubleshooting . . . . . 104  
Track/Seat Warning. . . . . . . . . . . . . . 24  
Traction Products. . . . . . . . . . . . . . . . 36  
Transporting the Snowmobile . . . . . 102  
Troubleshooting, Belt Wear . . . . . . 105  
Troubleshooting, Engine . . . . . 106-108  
Troubleshooting, Suspension. . . . . . 104  
Tune-Up. . . . . . . . . . . . . . . . . . . . . . . 85  
T
V
Throttle Lever . . . . . . . . . . . . . . 39, 55  
Throttle Safety Switch. . . . . . . . 39, 54  
Tool Kit . . . . . . . . . . . . . . . . . . . . . . 85  
Torque Stop . . . . . . . . . . . . . . . . . . . 84  
Towing. . . . . . . . . . . . . . . . . . . . . . . 58  
Track  
Vehicle Identification Numbers. . . . . . 6  
W
Warranty, Engine Emissions . . 116-117  
Windchill/Temperature Charts . . . . . 22  
Alignment . . . . . . . . . . . . . . . . 90  
Cooling . . . . . . . . . . . . . . . . . . 47  
Damage . . . . . . . . . . . . . . . . . . 42  
Inspection. . . . . . . . . . . . . . . . . 86  
Lubrication. . . . . . . . . . . . . . . . 87  
Tension . . . . . . . . . . . . . 33, 88-89  
Warm-Up. . . . . . . . . . . . . . . . . 48  
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