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Polaris 340 Touring Owner's Manual

Polaris 2007 snowmobile owner's manual
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  • Page 2 For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone (763) 417-8650 Fax (763) 542-0599 Part No. 9920449 Rev 02 Printed in USA...
  • Page 3 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. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 4 Polaris enthusiasts. Be sure to visit us online at www.polarisindustries.com for the latest news, new product introduc- tions, upcoming events, career opportunities and more. Here at Polaris we proudly produce an exciting line of utility and recre- ational products. • Snowmobiles •...
  • Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 6: Table Of Contents

    Polaris Products..... . . 128 Troubleshooting ..... . . 129 Warranty .

  • Page 7: Introduction

    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.

  • Page 8: Preservation Of The Environment

    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.

  • Page 9: Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.

  • Page 10: Operator Safety

    Always check major and vital safety components before every ride. All Polaris snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.
  • Page 11 SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track.

  • Page 12: Riding Position

    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.

  • Page 13: Survival Preparation

    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.

  • Page 14: Disabled Operators

    A decal on the console of these models indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only.

  • Page 15: Excessive Speed

    SAFETY Excessive Speed High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per sec- ond your machine travels.

  • Page 16: Driver Awareness

    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.
  • Page 17 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.

  • Page 18: Ice And Snow Build-Up

    Operator Safety Ice and Snow Build-up Ice and snow build-up may interfere with the steering of your machine, result- ing in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering.

  • Page 19: Driving Downhill

    SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the machine and keep it from rolling freely downhill.

  • Page 20: Drive Belt

    Operator Safety Driving in Hilly Terrain Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly terrain.

  • Page 21: Clutch Guard

    SAFETY Operator Safety 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 safety guard by removing it. Clutches Do not attempt to service the clutches.

  • Page 22: Inadequate Snow Conditions

    They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20_ F), Polaris recommends closing the upper hood closure. Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury.

  • Page 23: Driving Responsibly

    SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile condi- tions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the machine and with what it will and won't do under various conditions. Even seasoned driv- ers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
  • Page 24 Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WINDCHILL CHART (_F) Wind Speed Calm Frostbite in >> 30 min. WINDCHILL CHART (_C) Wind Speed Calm -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67...

  • Page 25: Clutch Cover Warning

    If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.

  • Page 26: Track Warning

    Entanglement with the track or a fall from seat back can result in severe injury or death. Passenger Warning Polaris touring models and the WideTrak are designed for the operator and one passenger. For more information on operating with a passenger, see page 11.

  • Page 27: Safety Decals And Locations

    SAFETY Safety Decals and Locations Standard Reverse Warning The Polaris WideTrak snow- mobile is equipped with stan- dard reverse. The reverse warning decal is located above the instrument housing: WARNING Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death.
  • Page 28 Safety Decals and Locations Electronic Reverse Warning Polaris snowmobiles equipped with electronic reverse have a reverse warning decal on the lower dash: 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: •...

  • Page 29: Operation Warning

    • To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, con- tact a Polaris dealer for a replacement. • This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control.

  • Page 30: Features

    Some Polaris snowmobiles are equipped with special features. Operat- ing controls and special feature controls are illustrated on this page. Not all models come with all special features. See your Owner's Manual Supplement. 1. Fuel Filler Cap 2. Ignition Switch 3.
  • Page 31 FEATURES 1. Hood 2. Headlight 3. Passenger Lumbar Adjuster 4. Windshield 5. Handlebar 6. Operator Seat 7. Passenger Seat 8. Taillights 9. Rear Bumper 10. Snow Flap 11. Passenger Grab Handle 12. Track 13. Suspension 14. Trailing Arm 15. Nosepan 16.

  • Page 32: Passenger Seat

    Passenger Seat The passenger seat features an adjustable lumbar support. To adjust for rider comfort, rotate the lumbar adjustment knob. On Touring models, the passenger seat and cargo bag are removable to provide open storage for transport- ing larger items. 1.

  • Page 33: The Perfect Fit

    THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.

  • Page 34: Shock Components

    The front springs can be changed if spring preload alone isn't sufficient and further adjustment is desired to control suspen- sion stiffness. See your Polaris dealer for more information. 1. Retainer 2. Shock Rod 3. Jounce Bumper 4. Body 5. Threaded Spring Pre-...

  • Page 35: Front Suspension Adjustments

    THE PERFECT FIT Front Suspension Adjustments Shock Damping (Indy Select Shock) Adjustments to the compression stiff- ness of Indy Select shocks can be made by turning the adjustment screw located near the base of the shock ( ). This adjustment is the easiest to per- form and it should be considered first.

  • Page 36: Spring Preload

    For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn't sufficient and fur- ther adjustment is desired to control suspension stiffness. See your Polaris dealer for more information. THE PERFECT FIT Preload...

  • Page 37: Rear Suspension Adjustments

    A suspension set up for trail riding would bot- tom out harshly on a snowcross 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.

  • Page 38: Suspension Performance Tips

    Bogie wheel kits are available from your dealer. • Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.
  • Page 39 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the EDGE rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement Take the first measurement with no rider and with the rear suspension at full extension.
  • Page 40 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments Rear Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information. The following information is provided only as a guideline to be used for initial suspension set-up.
  • Page 41 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving. Locate the adjust- ment screw near the base of the shock. In half-turn increments, turn the screw clockwise to increase compression valving and stiffen the ride, or counterclockwise to reduce compression and soften the ride.

  • Page 42: Suspension Coupling

    Contact your dealer for more information. Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of sus- pension coupling, these torque arms could move independently of each other.
  • Page 43 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments Suspension Coupling Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen- dent movement between the rear torque and the front torque arm.

  • Page 44: Weight Transfer During Acceleration

    EDGE 136 Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding condi- tions. To decrease weight transfer under acceleration (for improved corner- ing), rotate the RRSS to a higher position.
  • Page 45 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 machine to relieve the rear springs. 2. Slowly lower the machine and measure the distance between the ground and the running board.

  • Page 46: Handlebar Adjustment

    Handlebar Adjustment Follow these steps to adjust handle- bar angle at the handlebar block. 1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster block bolts (2). 2. Using a 7/16I (11 mm) wrench, loosen the four nuts (3) on the bottom of the adjuster block (turn handlebar to left or right for access to back nuts).

  • Page 47: Traction Products

    Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. NOTE: Polaris does not recommend the use of traction products on WideTrak snowmobiles. Use only Polaris traction products on your snowmobile. Track warran- ties are void if track damage or failure results from improper or exces- sive stud installation or the use of non-Polaris traction products.
  • Page 48 Traction Products nCarbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control.

  • Page 49: Wear Strips

    THE PERFECT FIT Traction Products Wear Strips To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. See your dealer for more information. Some models are manufactured with tunnel wear strips or wear strip coolers installed.
  • Page 50 Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements •...

  • Page 51: Pre-Ride Inspections

    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. Drive Belt Condition Steering System Recoil Rope...

  • Page 52: Before Starting The Engine

    Before Starting the Engine Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable snowmobiling experience.
  • Page 53 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 1/2I (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.
  • Page 54 PRE-RIDE INSPECTIONS Before Starting the Engine n Mechanical Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel (1.9 cm) Firmly depress the brake lever. Measure the distance ( ) between the lever and brake block.

  • Page 55: Parking Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock If your model is equipped with the parking brake lever lock, use the lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1.

  • Page 56: Steering System

    Before Starting the Engine n Steering System Ice and snow build-up may interfere with the steering of your machine, result- ing in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering.

  • Page 57: 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...
  • Page 58 Start the Engine and Check 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. Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF. Tether Switch If your machine has a tether switch, remove the tether from the switch to make sure the engine stops immediately.

  • Page 59: Operation

    OPERATION Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Before Starting the Engine beginning on page 49. 1.
  • Page 60 Premix the first tank of fuel with one pint of Polaris injection oil for each five gal- lons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

  • Page 61: Oil Injection System

    Engine lubrication comes from oil added to the fuel and oil injection systems. On Polaris snowmobiles equipped with a variable exhaust sys- tem (VES), Polaris highly recommends the use of only VES II 2 Cycle Oil. See the table below for additional oil recommendations. See page 128 for the part numbers of Polaris products.

  • Page 62: Track Warm-Up

    Track Warm-Up A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throt- tle during warm-up or when the track is free-hanging.

  • Page 63: Fuel Valve

    OPERATION Fuel Valve Turn the fuel valve clockwise to OFF to shut off the fuel supply. Turn the valve counter-clockwise to ON to turn the fuel supply on. Fuel Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. •...
  • Page 64 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 across the country, so we encourage the use of premium fuel when possible. Do not use fuel containing more than 10% ethanol (including E85).

  • Page 65: Fuel System Deicers

    RES. Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures.

  • Page 66: Low Oil Indicator Light

    When the oil reaches the low level mark, add one U.S. quart of recommended oil. See page 58 for oil recommenda- tions. NOTE: The Polaris oil cap on the oil bottle is vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.
  • Page 67 Either condition may be caused by improper carburetor adjustment. Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage. Always have your Polaris dealer perform any carburetor adjustments. WARNING...

  • Page 68: Jetting Guidelines

    Carburetion Jetting Guidelines Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. The carburetors are calibrated for an altitude of 0-2000 ft.

  • Page 69: Engine Stop Switch

    OPERATION Engine Stop Switch Push down on the engine stop switch ( ) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. 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.
  • Page 70 When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the machine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealer for service as soon as possible. WARNING OPERATION...

  • Page 71: Emergency Stopping

    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 66 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch Tether Switch (Option) WHAT IT DOES...

  • Page 72: Emergency Starting

    Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Snowmobiles equipped with electric start have a recoil for emergency starting. On non-electric-start models, if the recoil starter system fails, an emergency start strap is provided in the kit. 1.

  • Page 73: Reverse Operation

    OPERATION Reverse Operation 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.
  • Page 74 Reverse Operation Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. If your machine is running at an altitude of over 6000 feet, adjust the igni- tion setting as described on page 72. Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse.
  • Page 75 OPERATION Reverse Operation Electronic Reverse (PERCt) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button for one second and release. The engine will slow and begin to rotate forward. The light on the instrument panel will shut off.

  • Page 76: Daily Storage

    Daily Storage At the end of each ride, park the snow- mobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4I (10 cm) off the ground. Remove the key and cover the machine. Towing For your safety, do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions.

  • Page 77: Maintenance

    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.
  • Page 78 Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.
  • Page 79 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. 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.

  • Page 80: Coolant Level

    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 Clutch Alignment Offset...

  • Page 81: Auxiliary Shut-Off Switch (Engine Stop Switch)

    MAINTENANCE Periodic Maintenance Interval Table Item Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System 50, 97 Brake Fluid Pilot Air Screws Carburetor (synchronize) Idle RPM Throttle Lever Oil Pump Lever (synchronize) Throttle Cable Choke Cable Choke Vent Lines Throttle Position...

  • Page 82: Suspension Mounting Bolts

    Periodic Maintenance Interval Table Item Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fas- teners Suspension Shock Oil Cooling Fins and Shroud Drive Shaft Bearing Jackshaft Bearings Skags (Wear Bars) Ski Saddle/Spindle Bolts Ski Pivots Ski Spindle Steering Arm(s) Upper / Lower Steering Post Support Bracket Drive Chain Tension...
  • Page 83 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 128 for the part numbers of Polaris products.

  • Page 84: Driveshaft Bearing

    MAINTENANCE Lubrication EDGE 136 Rear Suspension WideTrak Rear Suspension Driveshaft Bearing Inject grease into the fitting on the speedome- ter sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps.

  • Page 85: Throttle Cable

    MAINTENANCE Lubrication Jackshaft Bearing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fit- ting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps).

  • Page 86: Gearcase Oil Level (Widetrak)

    (2) every 500 miles (800 km) and whenever checking or changing lubricant. Mixing brands or using non-recommended lubricants could result in exces- sive wear to chain, sprockets and bearings. Always use Polaris-recom- mended products for your vehicle. MAINTENANCE CAUTION...
  • Page 87 Maintain the oil level between the “safe” marks on the dipstick. Clean the magnetic plug on the dipstick whenever checking or changing oil. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 128 for the part numbers of Polaris products.

  • Page 88: Spark Plugs

    Spark Plugs A new engine can cause temporary spark plug fouling due to the preser- vative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your machine.
  • Page 89 MAINTENANCE Spark Plugs 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. NOTE: The tip should not be white.

  • Page 90: Intake Filters

    Intake Filters Operating the snowmobile with the intake filters removed may cause carbu- retor icing. The result will be poor fuel economy or carburetor malfunction. Always reinstall the intake filters before operating the snowmobile. The intake foam filter ( ) limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow.

  • Page 91: Oil Filter

    MAINTENANCE Fuel Filter/Fuel Lines See your Polaris dealer for replacement of the in-tank fuel filter every 1000 miles (or annually). Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fuel compounds may occur.

  • Page 92: Carburetor Adjustments

    It's your dealer's responsibility to make sure the correct main jet is installed. 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.

  • Page 93: Water/Sediment Trap Service

    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 at least every 2000 miles (3200 km) and inspected for contamination.

  • Page 94: Exhaust System

    Maintenance of the VES is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles (800-1600 km), bring the machine to an authorized Polaris dealer to have the VES disassem- bled, inspected, and cleaned. NOTE: To ensure maximum performance and minimize required main- tenance, follow the oil recommendation chart on page 58.
  • Page 95 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture. See page 128 for the part numbers of Polaris products. NOTE: Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.
  • Page 96 Cooling System (WideTrak) Coolant High Temperature Indicator Light The high temperature indicator light is controlled by a switch in the engine cooling system on liquid cooled models. If the engine coolant reaches a certain temperature, the switch completes a circuit that turns the light on.

  • Page 97: Flushing The Cooling System

    This service must be performed when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile.

  • Page 98: Bleeding The Cooling System

    Cooling System (WideTrak) Bleeding the Cooling System Steam and hot liquids will cause serious burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly.

  • Page 99: Drive Chain Tension

    MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.

  • Page 100: Brake Components

    Always replace brake pads when the brake pad material becomes thinner than the backing plate (approximately 1/16 Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, bring the machine to an authorized Polaris dealer for inspec- tion and adjustment. Brake Components 1. Brake Caliper 2.

  • Page 101: Brake Fluid

    Add the recommended brake fluid to bring the level up to the top of the fluid level mark on the inside of the reservoir. Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 128 for the part numbers of Polaris products.

  • Page 102: Bleeding The Hydraulic Brake System

    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. 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.

  • Page 103: Headlight Adjustment

    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.

  • Page 104: Headlight Bulb Replacement

    Lights NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol- moistened towel.
  • Page 105 MAINTENANCE Lights Headlight Bulb Replacement High Beam Style 1. Remove the wire harness (1). 2. Gasp the bulb (2) firmly and twist it 1/2 turn counterclockwise. 3. Remove the bulb from housing and replace with new bulb. 4. Place the bulb and housing back inside the hole and turn the housing 1/2 turn clockwise to lock into place.

  • Page 106: Clutch System

    Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated. Do not lubricate clutch bushings.

  • Page 107: Clutch Alignment Offset

    Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris rec- ommends that only O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor performance.

  • Page 108: Drive Belt Condition

    MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist.

  • Page 109: Drive Belt Removal

    MAINTENANCE Clutch System Drive Belt Removal Do not attempt to remove the drive belt after operating in reverse. The snow- mobile must be stopped after forward motion to prevent damage to compo- nents during belt removal. 1. Stop the engine after operating in a forward motion. 2.

  • Page 110: Drive Belt Installation

    Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rota- tion by positioning the identification numbers so that you can read them.

  • Page 111: Drive Belt Deflection

    MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pres- sure while measuring at point 2. This measurement should be 1 1/4I (3.2 cm).

  • Page 112: Torque Stop

    Clutch System Torque Stop If your snowmobile is equipped with an engine torque stop, periodi- cally check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010I-.030I (.25-.75 mm) from the engine case. Adjust if necessary, and lock the jam nut.

  • Page 113: Tool Kit

    Maintain the proper chain tension as outlined on page 96. Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Tool Kit A tool kit is included with each machine for emergency and routine maintenance.

  • Page 114: Track Inspection

    Track Track Inspection Broken track rods can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snow- mobile off the ground.

  • Page 115: Track Tension

    MAINTENANCE Track 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.
  • Page 116 Track Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 112. If the track needs adjustment: 5. Loosen the rear idler shaft bolt.

  • Page 117: Track Alignment/Condition

    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 machine with the track off the ground. 2.

  • Page 118: Steering System

    Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary. EDGE IFS WideTrak MAINTENANCE...

  • Page 119: Ski Alignment

    Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski align- ment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.

  • Page 120: Ski Skags

    Steering System n Ski Skags Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.

  • Page 121: Rail Slide Wear

    Steering System n Rail Slide Wear For ease of inspection, all Polaris rail slides (except WideTrak) have a wear limit indicator groove to indicate the minimum permissible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length.

  • Page 122: Rail Slide Condition

    Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the follow- ing items on a weekly basis or before any long trip: Check suspension mounting bolts for tightness.

  • Page 123: Cleaning And Preservation

    Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 128 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts.

  • Page 124: Clutch And Drive System

    Remove the drive belt and store in a cool dry location. To prevent oxida- tion on the clutch sheaves, lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant. NOTE: After storage, always use acetone or alcohol to remove the oil before reinstalling the drive belt.

  • Page 125: Engine And Carburetor Protection

    (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 3-5 on remaining cylin- ders.

  • Page 126: Electrical Connections

    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. 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.

  • Page 127: Battery Fluid

    MAINTENANCE Battery Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks. Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immedi- ate medical attention.

  • Page 128: Battery Removal

    Battery Battery Removal Improperly connecting or disconnecting battery cables can result in an explo- sion 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.

  • Page 129: Battery Installation

    MAINTENANCE Battery Battery Installation Batteries contain gases that can explode. If the battery vent tube is pinched or kinked, battery gases could accumulate. Whenever removing or installing the battery, disconnect the negative (black) cable first and reinstall the nega- tive cable last to avoid the possibility of explosion. Battery electrolyte contains acid.

  • Page 130: Battery Storage

    Battery Battery Storage When your snowmobile is placed in storage for one month or more: • Remove the battery. • Charge it to the proper level. • Store it in a cool dry place. • Check and/or charge monthly. Before using the battery, take it to your dealer for testing and recharging. Batteries may freeze if not fully charged, resulting in cell damage.

  • Page 131: Polaris Products

    POLARIS PRODUCTS Part No. 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (gal.) 2872347 Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.)

  • Page 132: Troubleshooting

    Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine oper- Drive clutch binding ating RPM during acceleration or load variations Driven clutch mal- function Harsh drive clutch Drive belt worn or engagement...
  • Page 133 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive sys- Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain worn, sprocket teeth bro- Poor low RPM per- Worn drive belt formance Excessive belt/...
  • Page 134 • Make sure fuel tank contains fuel. • Ice may be in fuel line, filter or pump. Add isopropyl alcohol to fuel system. 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".
  • Page 135 TROUBLESHOOTING EDGE 136 Suspension Problem Solution Rear suspension bot- • Increase torsion spring preload toms too easily • Increase rear shock compression damping by turning • Increase torsion spring wire diameter (see your dealer) Rides too stiff in rear • Check for binding suspension shafts and grease all pivot •...

  • Page 136: Drive Belt Troubleshooting

    Drive Belt Troubleshooting Causes Driving at low RPM Insufficient warm-up Towing at low RPM Riding with high RPM and slow speed (8000 RPM/10 MPH) Ice and snow build-up between track and tunnel Poor engine performance Loading machines onto trailers Clutch malfunction Slow, easy clutch engage- ment TROUBLESHOOTING...

  • Page 137: Warranty

    Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information con- tained in this manual. Your dealer is also familiar with Polaris policies and pro- cedures and will be happy to assist you.
  • Page 138 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. Polaris warranty will aid in notifying the proper owner when a unit is recovered. WARRANTY...

  • Page 139: Limited Warranty

    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.

  • Page 140: Engine Oil

    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).
  • Page 141 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.
  • Page 142 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.
  • Page 143 • 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.
  • Page 144 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.
  • Page 145 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.
  • Page 146 Environmental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068. Polaris warrants that the engine is free from defects in materials and workmanship that would cause it to fail to meet these regulations. The warranty period for this emissions...
  • Page 147 Polaris. Owners are responsible for performing the scheduled maintenance identified in the owner's manual. Polaris can deny an emissions warranty claim if any specified critical emissions-related maintenance is not performed. Performance of other scheduled main- tenance is strongly recommended, but is not necessary to keep the emissions-related warranty valid.

  • Page 148: 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 TECHNICIAN (KM) 150 mi. (240 km) 500 mi.
  • Page 149 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 150 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 151: Index

    INDEX Accessories ....47 Air Pollution ....5 Airbox Warning .
  • Page 152 Passenger Warning ....23 Polaris Products ....128 Preload, Front Shock Spring..33 Pre-Ride Checklist .
  • Page 153 INDEX Storage, Daily ....73 Storage, Extended ..120-123 Studs ......44 Survival Preparation .

This manual is also suitable for:

Trail touring deluxe340 touring 2007Trail touring dlx 2007Widetrak 2007

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