1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Offroad Vehicle
  5. 800 Pro X
  6. Owner's manual

Polaris 800 Pro X Owner's Manual

Polaris 2004 snowmobile owner's manual
Hide thumbs
Table of Contents

Advertisement

Quick Links

2004
2004
PRO X
PRO X
Snowmobiles
Snowmobiles
Owner's Manual
Owner's Manual
for Vehicle Maintenance
for Vehicle Maintenance
and Safety
and Safety

Advertisement

Table of Contents
loading

Related Manuals for Polaris 800 Pro X

Summary of Contents for Polaris 800 Pro X

  • Page 1 2004 2004 PRO X PRO X Snowmobiles Snowmobiles Owner's Manual Owner's Manual for Vehicle Maintenance for Vehicle Maintenance and Safety and Safety...
  • Page 2 Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust, which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm, onto the snow on...
  • Page 3 What’s the hottest thing on snow? A Polaris owner’s Web site, designed just for YOU! Check it out... www.polarisindustries.com/owner Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out...
  • Page 4 Copyright 2003 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 discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 5 S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...

  • Page 7: Table Of Contents

    ......This section defines your role, and your dealer’s role, in your snowmobile’s regular maintenance. Polaris Products Troubleshooting This section is a quick reference guide to solving problems.

  • Page 9: Introduction

    Important Notes for Owners and Drivers n After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. n The illustrations and photos used in this manual are general representations. Your model may differ. n Follow the maintenance program outlined in this manual.

  • Page 10: 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 11: 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. If both keys are lost, the ignition switch must be replaced.

  • Page 12: 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 symbols 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 personal injury.
  • Page 13 We strongly recommend that the operator 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 14: Safety

    SAFETY Operator Safety Stay Away From Moving Parts Be alert when riding, and remain properly seated to stay clear of the 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.

  • Page 15: Riding Position

    Operator Safety Riding Position Improper riding position may seriously reduce your ability to control the machine and may result in serious injury or death. Always be properly seated and in position to control your vehicle. Operating a snowmobile requires skill and balance for proper control. Rider positions may vary from person to person as each becomes more skilled;...

  • Page 16: Excessive Speed

    SAFETY Operator Safety Excessive Speed High speed driving, especially at night, could result in serious personal 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.

  • Page 17: 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 18: Driving In Hilly Terrain

    SAFETY 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. Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over.

  • Page 19: Driving Downhill

    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: Powder Snow Operation

    SAFETY Operator Safety Powder Snow Operation Moveable hood closures are included on some Polaris snowmobiles. 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.

  • Page 21: Driving On Slippery Surfaces

    Operator Safety Driving on Slippery Surfaces Driving on ice or hard-packed snow reduces steering and braking control, which may result in serious injury or death. Slow down and use caution. Excessive shifting of operator body weight when turning on hard-packed snow or ice may lead to loss of vehicle control and result in serious injury or death.

  • Page 22: Rider Capacities

    Rider Capacities Polaris PRO X snowmobiles are designed for a single rider only. A decal on the console of these models indicates single rider operation. See page 24 for decal location.

  • Page 23: Driving Responsibly

    Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions 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 drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers.

  • Page 24: Windchill/Temperature Charts

    SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART (°F) Estimated Wind Speed in MPH Speed in MPH Calm Wind Speeds Great- er Than 40 MPH Have Little Added Have Little Added Clothed Person)

  • Page 25: Safety Decals And Locations

    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

    Safety Decals and Locations Track Warning The track warning decal is located on the rear of the tunnel: Passenger Warning Polaris PRO X snowmobiles are designed for one operator only. A “No Passenger” warning decal is located on the console:...
  • Page 27 SAFETY Safety Decals and Locations Reverse Warning Some Polaris snowmobiles are equipped with reverse. These models will have a reverse warning decal on the lower dash. WARNING AVERTISSEMENT...

  • Page 28: Operation Warning

    SAFETY Safety Decals and Locations Operation Warning Operation warning decals are present on the console of all Polaris snowmobiles, in both French and English. WARNING...
  • Page 29 SAFETY Safety Decals and Locations Operation Warning AVERTISSEMENT...

  • Page 30: Features And Controls

    FEATURES AND CONTROLS Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on the following pages. Not all models come with these features. Refer to your Owner’s Manual Supplement for a list of specific features on your machine. Accessories are available from your Polaris dealer.
  • Page 31 FEATURES AND CONTROLS...

  • Page 32: Features And Controls

    FEATURES AND CONTROLS 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Storage Compartment/Trunk 7. Taillights 8. Rear Bumper 9. Snow Flap 10. Track 11. Suspension 12. Trailing Arm 13. Nosepan 14. Front Bumper 15. Skis...

  • Page 33: D.e.t. Troubleshooting

    Detonation Elimination Technology (D.E.T.) Some Polaris snowmobiles are equipped with a detonation sensor that monitors the engine and responds to detonation by automatically reducing the engine timing. When activated, the “DETONATION FLASH” indicator (A) will flash in the lower right-hand area of the tachometer.

  • Page 34: The Perfect Fit

    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.

  • Page 35: Shock Absorber Components

    Front Suspension Adjustments Always verify ski alignment before making adjustments to the IFS. See page105 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.

  • Page 36: The Perfect Fit

    THE PERFECT FIT Front Suspension Adjustments Adjusting Front Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure springs on both the left and right sides of the machine are at the same adjustment.

  • Page 37: Shock Valving

    Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a Polaris dealer. Front Springs For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn’t sufficient and...

  • Page 38: Suspension Performance Tips

    Bogie wheel kits are available from your dealer. S 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 PRO X Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the PRO X rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension.
  • Page 40 THE PERFECT FIT PRO X Rear Suspension Adjustments Rear Torsion 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. Contact your dealer for more information.
  • Page 41 THE PERFECT FIT PRO X Rear Suspension Adjustments Clicker Shock The position sensitive clicker shock is available as an option on some models. Adjustments to the compression damping are made by turning the clicker knob (A) on the shock reservoir. Position #1 is the softest, or least compression damping.

  • 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 suspension coupling, these torque arms could move independently of each other.
  • Page 43 THE PERFECT FIT PRO X Rear Suspension Adjustments 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 independent movement between the rear torque and the front torque arm.

  • Page 44: Weight Transfer During Acceleration

    THE PERFECT FIT PRO X Rear Suspension Adjustments Weight Transfer During Acceleration PRO X Rear Rear Scissor Stop (RRSS) The preferred method for controlling weight transfer during acceleration of the PRO X rear suspension is by adjusting the RRSS. Use the scissor stop tool (1) located in your tool kit to make the adjustments.

  • Page 45: Handlebar Adjustments

    Handlebar Adjustments Handlebar with Riser Block 1. Remove the handlebar cover to expose the handlebar mounting hardware. 2. Using a 1/2” wrench, loosen the two bolts on the bottom of the riser or the two bolts on the top of the riser, depending on the type of adjustment required.
  • Page 46 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. See your dealer for a complete list of accessories. NOTE: The accessory tether switch is available for all models. Order PN 2870668.

  • Page 47: Traction Products

    THE PERFECT FIT Accessories Traction Products Another way to tailor your machine is to install traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance.
  • Page 48 Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products. Loss of control can result in serious personal injury or death.

  • Page 49: Wear Strips

    Accessories Wear Strips Polaris PRO X models are manufactured with tunnel wear strips or wear strip coolers installed. To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Wear strips are designed for a specific stud length. See your dealer’s studding chart for recommended traction accessories.

  • Page 50: Pre-Ride Inspections

    PRE-RIDE INSPECTIONS 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. We’ve attempted to provide as much information as possible to alert you to the safety requirements of snowmobiling.

  • Page 51: Hydraulic Brakes

    Also check for the presence of air in the fluid system. Refer to page 93 for more information, or see your dealer for service. Replace brake fluid at least every two years with Polaris DOT 3 high temperature brake fluid. All DOT 3 brake fluid is not alike. Use only Polaris brake fluid.

  • Page 52: Pre-Ride Inspections

    PRE-RIDE INSPECTIONS Before Starting the Engine Park Brake Lever Lock Your snowmobile may have a park brake lever lock located over the brake lever. Use the brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less.

  • Page 53: Track Inspection

    Before Starting the Engine Check for Proper Operation of Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated.

  • Page 54: Start The Engine And Check

    PRE-RIDE INSPECTIONS Start the Engine and Check n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and allow starting of the engine. n Tether Switch: If your machine has a tether switch, make sure the engine shuts off when the tether is removed from the switch.

  • Page 55: Operation

    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.

  • Page 56: Starting A Warm Engine

    No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

  • Page 57: Operation

    RPM and throttle valve opening. Variable Exhaust System We recommend the use of Polaris VES two-cycle oil in all snowmobile engines equipped with variable exhaust valves (see chart below). Oil Recommendations The only source of engine lubrication for your engine comes from lubrication added to the fuel and oil injection systems.

  • Page 58: Track Warm-Up

    OPERATION A loose track or flying debris could cause serious personal 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 throttle during warm-up or when the track is free-hanging.
  • Page 59 Fuel 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 smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 60: Premium Fuel Switch

    OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used. Most Polaris snowmobile engines are designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline, but a higher octane fuel (premium 91 octane) is preferred for the PRO X models.

  • Page 61: Fuel Reserve Capacity

    (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 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures.

  • Page 62: Low Oil Indicator Light

    Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris VES oil in all snowmobile engines equipped with variable exhaust valves. Never mix brands.

  • Page 63: Jetting Guidelines

    In higher elevations and higher temperatures, the air is less dense. Carburetors on most Polaris models are calibrated for an altitude of 0-2000 ft (0-600 meters) and ambient temperatures between -10 to +10 F (-23 to -12 C).

  • Page 64: Engine Stop Switch

    OPERATION Engine Stop Switch Push down on the engine stop switch (A) 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.

  • Page 65: Throttle Lever

    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...

  • Page 66: Emergency Stopping

    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 62 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) Excessive or repetitive use of brakes for high speed stops will...

  • Page 67: Emergency Starting

    Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. If the recoil starter system fails, an emergency start strap is provided in the kit. Serious injury can result from wrapping the start strap around your hand while using the emergency starting procedure.

  • Page 68: Reverse Operation

    OPERATION Reverse Operation Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Always look behind the vehicle before and while backing. Always avoid sharp turns. Shift to or from reverse only when stopped. Always apply throttle slowly.

  • Page 69: Altitude Setting

    OPERATION Reverse Operation Electronic Reverse (PERCt) Disengaging Reverse Push the yellow reverse button on the handlebar for one second and release. The engine will slow and and begin to rotate forward. The light on the instrument panel will shut off. Make sure the area around your vehicle is clear and apply throttle slowly until you’re sure the machine is in forward gear.
  • Page 70 OPERATION Towing For your safety, do not attempt to using the tow hitch until you’ve read the following warnings and understand the proper hitch functions. 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.

  • Page 71: Maintenance

    Personal safety is critical when attempting to service or adjust your snowmobile. If you’re not familiar with safe service or adjustment procedures and the use of tools, or if you don’t feel comfortable performing these tasks yourself, contact an authorized Polaris dealer for service.

  • Page 72: Maintenance Chart

    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 Check brake operation and...

  • Page 73: Maintenance

    Grease center steering arm(s) Lubricate steering post support bracket and pivot (aerosol) Check cylinder base stud torque on all Polaris engines. (Specifica- tion: 32 ft. lbs ± 2 ft. lbs.) (Dealer) Grease lower steering post pivot Grease driveshaft bearing (always perform before storage)

  • Page 74: Maintenance Log

    This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. 150 Mile (240 km) Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date 500 Mile (800 km) Maintenance Inspection...
  • Page 75 Maintenance Log Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service MAINTENANCE Mileage Mileage...

  • Page 76: Polaris Products

    S Grease the steering post lower pivot. S Grease the rear suspension pivot shafts (raise the rear of unit). A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmobiles. See page 112.
  • Page 77 MAINTENANCE Lubrication The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the suspension.

  • Page 78: Throttle Cable

    MAINTENANCE Lubrication Jackshaft Bearing Greasing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. 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 79: Chaincase Oil Level

    “safe” marks on the dipstick (A). Add Polaris synthetic chaincase oil through the dipstick opening. Do not overfill. See page 112 for the part numbers of Polaris products. Flush the chaincase after the first 500 miles, then every 1000 miles or seasonally.

  • Page 80: Spark Plugs

    Owner’s Manual Supplement for specific information. S Spark plug torque is 18-22 ft. lbs. (24-30 Nm). S Always carry spare spark plugs in case of an emergency. Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. CAUTION CAUTION...
  • Page 81 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. A hot exhaust system and engine can cause serious burns.

  • Page 82: Intake Filter

    MAINTENANCE Intake Filter 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. NOTE: These illustrations are general representations. Your model may differ.

  • Page 83: Water Pump Belt Inspection

    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 disassembled, inspected, and cleaned. NOTE: To ensure maximum performance and minimize required maintenance, follow the oil recommendation chart on page 55.

  • Page 84: Water/Sediment Trap Service

    MAINTENANCE Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained at least every 1000 miles (1600 km) and inspected for contamination.

  • Page 85: Oil Filter

    Fuel Filter/Fuel Lines Inspect the in-tank fuel filter (1) and fuel lines regularly. Give special attention to the system’s fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds may occur. Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines.
  • Page 86 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. The frequency at which the carburetors are synchronized or balanced is important.

  • Page 87: Exhaust System

    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.

  • Page 88: Coolant Level

    MAINTENANCE Engine Cooling - Liquid Cooled Models Coolant Mixture The coolant supplied in the system is a 50/50 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing at temperatures to -34° F (-37° C). If greater protection is required, the percentage of antifreeze to water may be increased.

  • Page 89: Flushing The Cooling System

    50/50 or 60/40 mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile. Steam and hot liquids will cause serious burns to your skin.

  • Page 90: Bleeding The Cooling System

    MAINTENANCE Engine Cooling - Liquid Cooled Models Bleeding the Cooling System If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced.

  • Page 91: Drive Chain Tension

    Drive Chain Tension 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. 2. Loosen the adjuster bolt jam nut (A).

  • Page 92: Hydraulic Brake Inspection

    MAINTENANCE Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Firmly depress the brake lever and measure the clearance between the lever and handlebar grip (A). This distance, called brake lever reserve, should be no less than 1/2″ (1.3 cm). Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16″).

  • Page 93: Brake Components

    5. Brake Pad Material (Replace when thickness is less than 1/16″). Excessive Brake Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as described on page 90, the machine should be returned to an authorized Polaris dealer for inspection and adjustment.

  • Page 94: Brake Fluid

    Maintain the brake fluid level between the MIN and MAX marks on the master cylinder reservoir. Use only Polaris DOT 3 high temperature brake fluid. See page 112 for the part numbers of Polaris products. WARNING WARNING...

  • Page 95: 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.

  • Page 96: Headlight Adjustment

    MAINTENANCE Headlights Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure: 1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall.
  • Page 97 Headlights 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. Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer.

  • Page 98: 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 99: Drive Belt Removal

    Clutch System Periodically check the condition and tension of the drive belt, and always carry a spare belt. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. The following procedures apply to standard, electronic reverse and TEAM driven clutches.

  • Page 100: Drive Belt Adjustment

    MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4”. Drive Belt Adjustment 1.

  • Page 101: Oil Level

    Always keep the tool kit with the snowmobile. If necessary, a replacement tool kit may be purchased from your Polaris dealer. NOTE: The tools and maintenance items mentioned in this book, as well as a long line of other Polaris accessories, are available at your Polaris dealer.

  • Page 102: For Your Protection

    STrail Map SFirst Aid Kit 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. SExtra Set of Spark Plugs SExtra Oil SWinter Survival Kit SOwner’s Manual...

  • Page 103: Track Tension

    Track Maintenance 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 running. Track Tension Track adjustment is critical for proper handling. Always maintain correct tension and alignment.

  • Page 104: Track Alignment

    MAINTENANCE Track Maintenance f the track needs adjustment (continued): 8. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new. 9. Start machine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brakes). 10.

  • Page 105: Track Lubrication

    Track Maintenance Track Inspection Broken track rods are a serious safety hazard. They 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. Using a hoist, safely lift and support the rear of the snowmobile off the ground.

  • Page 106: Steering System

    MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all fasteners and tighten if necessary. Specifically check fasteners marked with a...

  • Page 107: Ski Alignment

    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.

  • Page 108: Ski Skags

    MAINTENANCE Steering System 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 109: Suspension Maintenance

    MAINTENANCE Suspension Maintenance Hi-Fax Wear Check Hi-fax wear by measuring the thickness at several points along the rail (A). Replace Hi-fax when a thickness of 7/16″ (1.1 cm) is reached. Take the machine to your dealer for Hi-fax replacement. 7/16″ (1.1 cm)

  • Page 110: Cleaning And Preservation

    MAINTENANCE Suspension Maintenance 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 following items on a weekly basis or before any long trip: n Check rear idler wheel bolts for tightness.

  • Page 111: Clutch And Drive System

    See page 112. Always add Premium Carbon Clean or a fuel conditioner/stabilizer to the fuel tank. See page 112 for the part numbers of Polaris products. Follow the instructions on the can, running the engine for five minutes to get additives through the entire fuel system.

  • Page 112: Electrical Connections

    (BDC), the lowest position in the cylinder. On twin cylinder 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 cylinders.

  • Page 113: Transporting The Snowmobile

    Extended Storage Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely. See illustration. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Turn the fuel valve clockwise to OFF to shut off the fuel supply (1).

  • Page 114: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2874438 VES II Synthetic 2-Cycle Oil (qt.) 2874439 VES II Synthetic 2-Cycle Oil (gal.) Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant (qt.) 2872951 Synthetic Chaincase Lubricant (12 oz.)

  • Page 115: Troubleshooting

    Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Erratic engine Drive clutch binding operating RPM during accelera- tion or load Driven clutch variations malfunction Harsh drive Drive belt worn or clutch too narrow...
  • Page 116 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Noise in drive Broken drive clutch components system Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose or worn, sprocket teeth broken Poor low RPM Worn drive belt performance Excessive belt/sheave clearance...
  • Page 117 -Make sure the fuel valve is “ON”. Check tank level and fill up with correct 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 continually backfires”.

  • Page 118: Suspension Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension -Increase torsion spring preload -Increase rear shock compression damping by turning screw bottoms too easily clockwise -Increase torsion spring wire diameter (see your dealer) Rides too stiff in -Check for binding suspension shafts and grease all pivot points rear -Decrease torsion spring preload adjustments...

  • Page 119: Belt Troubleshooting

    Belt Troubleshooting Belt Wear/Burn 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 en- gagement...

  • Page 120: Warranty

    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. 5. Details of trouble experienced 6.

  • Page 121: 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 122 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 123 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 124 S Failures caused due to improper adjustments. Failure due to unauthorized service. S 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. S Failure due to use of unauthorized parts or modifications.
  • Page 125 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 126: Index

    Accessories ....Air Box ......Bearings .
  • Page 127 ..... . . Plug Cleaning ....POLARIS PRODUCTS ... . Powder Snow Operation .

  • Page 128: Index

    Track Maintenance ... Track Tension ....Track Tension Data ....Track Warm-Up .
  • Page 129 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. 9918227 Printed in USA...

This manual is also suitable for:

Pro x 2004

Table of Contents