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Polaris 9919078 Owner's Manual For Maintenance And Safety

Polaris 2005 snowmobile owner's manual
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  • Page 3 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust, which contain chemicals known to the State of California to cause cancer and birth defects or other...
  • Page 5 Copyright 2004 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 6 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

    Maintenance 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. Warranty ....... .

  • Page 8: 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 9: 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 10: Vehicle Identification Numbers

    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 11: 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 12: Operator Safety

    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 13: Riding Position

    SAFETY Operator Safety Stay Away From Moving Parts WARNING Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious personal injury or death. We recommend having your dealer perform track service and alignment procedures.

  • Page 14: Survival Preparation

    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 conditions you may encounter.

  • Page 15: 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. See page 24 for decal location.

  • Page 16: Excessive Speed

    Operator Safety Excessive Speed WARNING 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 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: S Take an avalanche class S Travel with experienced people S Travel on designated trails S Make sure each person is equipped with a shovel, probe and avalanche beacon.

  • Page 19: Ice And Snow Build-Up

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

  • Page 20: Driving In Hilly Terrain

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

  • Page 21: 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 22: Intake Silencer

    Maneuverability will change for lighter operators or machines designed to carry a load or a passenger. Maintenance Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 76 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

  • Page 23: 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 24: 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 25 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 26: 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 27: Track Warning

    The decal specifies the maximum recommended weight capacity for the carrier. Never exceed the maximum recommended weight capacity for your machine. 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 12.
  • Page 28 SAFETY Safety Decals and Locations Standard Reverse Warning The Polaris WideTrak snowmobile is equipped with standard reverse. The reverse warning decal is located above the instrument housing.
  • Page 29 SAFETY Safety Decals and Locations Electronic Reverse Warning Polaris snowmobiles equipped with electronic reverse will have the electronic reverse warning decal. WARNING AVERTISSEMENT...

  • Page 30: Operation Warning

    SAFETY Safety Decals and Locations Operation Warning Operation warning decals are present on WARNING the console of all Polaris snowmobiles, in both French and English. Touring Models WARNING WideTrak...
  • Page 31 SAFETY Safety Decals and Locations Operation Warning AVERTISSEMENT Touring Models AVERTISSEMENT WideTrak...

  • Page 32: Features

    Some Polaris snowmobiles are equipped with special features. Operating controls and special feature controls are illustrated on this page. Not all models come with all special features. Refer to your Owner’s Manual Supplement for the features on your machine. 1. Fuel Filler Cap 2.
  • Page 33 FEATURES 1. Hood 2. Headlight 3. Passenger Lumbar Adjuster (Touring models) 4. Windshield 5. Handlebar 6. Operator Seat 7. Passenger Seat 8. Trunk Cover 9. Taillights 10. Rear Bumper 11. Snow Flap 12. Passenger Grab Handle 13. Track 14. Suspension 15.

  • Page 34: 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

    THE PERFECT FIT Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 120 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. For the best ride, the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming.

  • Page 36: Shock Damping

    THE PERFECT FIT Front Suspension Adjustments Shock Damping Adjustments to the compression stiffness of Indy Select or RydeFX SOLO shocks can be made by turning the adjustment screw (Select) or actuator (SOLO), located near the base of the shock (A). This adjustment is the easiest to perform and it should be considered first.
  • Page 37 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 the springs on both the left and right sides of the machine are at the same adjustment. To increase front shock spring preload, grasp the spring and turn it to the right.

  • Page 38: 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 39: Suspension Performance Tips

    S When riding on ice or hard-packed snow, adding a set of bogie wheels to the rail may enhance the machine’s performance. Bogie wheel kits are available from your dealer. S Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated.
  • Page 40 Edge 136 Rear Suspension Adjustments (Indy 340 Touring) 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 X. Take the first measurement with no rider and with the rear suspension at full extension.

  • Page 41: Rear Spring Tension

    THE PERFECT FIT Edge 136 Rear Suspension Adjustments (Indy 340 Touring) 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. Contact your dealer for more information.

  • 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 Edge 136 Rear Suspension Adjustments (Indy 340 Touring) Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop 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

    Edge 136 Rear Suspension Adjustments (Indy 340 Touring) Weight Transfer During Acceleration Rear Rear Scissor Stop (RRSS) The preferred method for controlling weight transfer during acceleration of the EDGE rear suspension is by adjusting the RRSS. The RRSS is located in the best overall trail riding position when delivered from the factory.
  • Page 45 THE PERFECT FIT Edge Touring Suspension (ETS) Adjustments Torsion Springs Two torsion springs are used on the rear arm of the ETS. Preload adjustments can be made by turning the rectangular adjusters with a spark plug wrench. The firm torsion spring should be used if frequent bottoming is encountered during two up riding on rough trails.
  • Page 46 Edge Touring Suspension (ETS) Adjustments Initial Setup and Calibration The following information has been compiled to assist you in tuning your ETS to its maximum potential. The Ride Control Adjuster (RCA) 1. Refer to the initial setup reference chart (located under the hood of your snowmobile and on page 42) to determine the desired RCA position.
  • Page 47 THE PERFECT FIT ETS ACE Adjustments The ETS ACE (Adjustable Control Electronics) is a new feature available for some ETS rear suspensions. It enables a rider to easily adjust the suspension for weight and riding style. The ETS ACE is an electronically controlled module that replaces the standard ETS RCA.
  • Page 48 THE PERFECT FIT ETS ACE Adjustments ETS ACE Settings IMPORTANT NOTES: The time to move one position can take up to 12 seconds depending on the rear shock loads. Due to alternator limitations, the ACE module will operate only at engine speeds above 3500 RPM.
  • Page 49 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 50: Handlebar Adjustment

    Handlebar Adjustment Follow these steps to adjust the handlebars for a personal fit. 1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts (A). 2. Using a 7/16″ (11 mm) wrench, loosen the four nuts on the bottom of the adjuster block (turn handlebar to left or right for access to back nuts).
  • Page 51 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories.

  • Page 52: 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. NOTE: Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products.
  • Page 53 Accessories 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. CAUTION Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage.

  • Page 54: Wear Strips

    Accessories Wear Strips To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Several wear strips are available. See your dealer for more information. Some models are manufactured with tunnel wear strips or wear strip coolers installed.

  • Page 55: 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 referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Drive Belt Condition Recoil Rope Coolant Level...

  • Page 56: Before Starting The Engine

    Before Starting the Engine WARNING Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and refer to it often. We’ve attempted to provide as much information as possible to alert you to the safety requirements of snowmobiling.

  • Page 57: Hydraulic Brakes

    Also check for the presence of air in the fluid system. Refer to page 105 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 58: Brake Lever Travel

    Before Starting the Engine Mechanical Brakes Brake Lever Travel Firmly depress the brake lever. Measure the distance (A) between the lever and brake block. The distance should be no more than 3/4″ (1.9 cm). If the distance is greater than this recommendation, the brake cable must be adjusted.

  • Page 59: Track Inspection

    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. Check Seat Latches If your snowmobile is equipped with a removeable seat, ensure that the...

  • Page 60: Start The Engine And Check

    Start the Engine and Check n Transmission: Make sure the reverse is not engaged before starting your machine. n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and start the engine.

  • Page 61: Operation

    OPERATION Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 53. Starting a Cold Engine (Manual Start) Do not depress the throttle until the engine starts.

  • Page 62: Starting A Warm Engine

    Starting the Engine Starting a Cold Engine (Electric Start) Do not depress the throttle until the engine starts. 1. Flip choke toggle to FULL ON. 2. Pull kill switch (shut-off switch) up to RUN. 3. Turn key to START and crank engine. 4.

  • Page 63: Engine Break-In

    No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of 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 64: Oil Injection System

    RPM and throttle valve opening. Variable Exhaust System We recommend the use of Polaris VES II 2-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 65: Track Warm-Up

    OPERATION Track Warm-Up WARNING 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 66: Slide Rail And Track Cooling

    Slide Rail and Track Cooling CAUTION Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces.

  • Page 67: Premium Fuel Switch

    OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used. 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.

  • Page 68: 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 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures.

  • Page 69: Low Oil Level

    Always do a visual check of the oil level when refueling. When the oil reaches the low level mark, add one U.S. quart of recommended oil. The Polaris oil cap on the oil tank may be vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.

  • Page 70: 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.

  • Page 71: Engine Stop Switch

    OPERATION n 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 72: 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. OPERATION...

  • Page 73: Passenger Seat

    OPERATION Passenger Seat The passenger seat features an adjustable lumbar support. To adjust for rider comfort, rotate the lumbar adjustment knob (A). The passenger seat and trunk cover are removeable. Removing the cover and seat will provide open storage for transporting larger items.

  • Page 74: Ignition Switch

    Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 68 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) WARNING...

  • Page 75: Emergency Starting

    OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Machine’s 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. WARNING Serious injury can result from wrapping the start strap around your hand while using the emergency starting procedure.

  • Page 76: Reverse Operation

    Reverse Operation WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. S Always look behind the vehicle before and while backing. S Always avoid sharp turns. S Shift to or from reverse only when stopped. S Always apply throttle slowly.
  • Page 77 OPERATION Reverse Operation Electronic Reverse (PERCt) Electronic reverse will activate only if the engine is below 4000 RPM (3000 RPM on fan cooled models). If your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described below (Altitude Settings).

  • Page 78: Daily Storage

    The track should be suspended approximately 4″ (10 cm) off the ground. Remove the key and cover the machine. Polaris has accessory covers NOTE: and track stands available to fit all models. See your dealer for more information.

  • Page 79: 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 80 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 Offset Alignment...
  • Page 81 MAINTENANCE Periodic Maintenance Interval Table Item Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake fluid Pilot Air Screws Carburetor (synchronize) Idle RPM Throttle Lever Oil Pump Lever (synchronize) Throttle Cable Choke Cable Vent Lines Throttle Position Sensor Choke Fuel Filter...

  • Page 82: Taillight/Brakelight/Headlight

    Periodic Maintenance Interval Table Item Auxiliary Shut-Off Switch Throttle Safety Switch Ignition Switch Taillight Brakelight Headlight Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Suspension Shock Oil Cooling Fins and Shroud Drive Shaft Bearings Jackshaft Bearings Skags (Wear Bars) Ski Saddle/Spindle Bolts Ski Pivots Ski Spindle...

  • Page 83: Tether Switch/Strap

    MAINTENANCE Periodic Maintenance Interval Table Item Rear Suspension Pivot Shafts Camber Alignment Radius Rod Bushings Handlebar Centering Tether Switch and Strap Track Alignment Track Tension Front Limiter Strap Hi-Fax Condition Chaincase Oil Gearcase Oil I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace Page...

  • Page 84: 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 85: Maintenance Log

    MAINTENANCE 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 Mileage Mileage...
  • Page 86 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 132. Aerosol...
  • Page 87 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 88 MAINTENANCE Lubrication ETS ACE Suspension WideTrak Suspension...

  • Page 89: Jackshaft Bearing Greasing

    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 90: Throttle Cable

    MAINTENANCE Lubrication Throttle Cable Lubricate the throttle cable (1) lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown. Choke and Cable Lubricate the choke slide (2) and cables lightly with oil or grease. Before turning the engine off, operate the choke intermittently to draw moisture out of the choke plunger area and reduce the...
  • Page 91 To check the oil level, place the machine on a level surface. The oil level should be between the “safe” marks on the dipstick (A). See your Polaris dealer for the recommended oil for your machine. Do not overfill. NOTE: Clean the magnetic plug (B)

  • Page 92: Chaincase Oil Level

    “safe” marks on the dipstick (A). Add Polaris chaincase oil (PN 2871280) through the dipstick opening. Do not overfill. See page 132 for the part numbers of Polaris products. Flush the chaincase after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.

  • Page 93: General Maintenance

    Owner’s Manual Supplement for specific information. S Spark plug torque is 18-22 ft. lbs. (24.4-30 Nm). S Always carry spare spark plugs in case of an emergency. CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs.
  • Page 94 General Maintenance Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. WARNING A hot exhaust system and engine can cause serious burns.

  • Page 95: Intake Filter

    MAINTENANCE General 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. CAUTION Operating the snowmobile with the intake filters removed may cause carburetor icing.

  • Page 96: Water Pump Belt Inspection

    Variable Exhaust System (VES) 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:...

  • Page 97: Water/Sediment Trap Service

    MAINTENANCE General 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 about every 1000 miles (1600 km) and inspected for contamination.

  • Page 98: Oil Filter

    General Maintenance Fuel Filter/Fuel Lines See your Polaris dealer for replacement of the in-tank fuel filter (1) 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.

  • Page 99: Carburetor Adjustments

    It’s your dealer’s responsibility to make sure the correct main jet is installed. CAUTION Operating the snowmobile with incorrect jetting can result in serious engine damage. Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly. Carburetor Adjustments The frequency at which the carburetors are synchronized or balanced is important.

  • Page 100: Exhaust System

    General Maintenance Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.

  • Page 101: Coolant Level

    MAINTENANCE General Maintenance 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 102: Flushing The Cooling System

    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.

  • Page 103: Bleeding The Cooling System

    MAINTENANCE General Maintenance Bleeding the Cooling System CAUTION If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced. Surge Tank Models 1.

  • Page 104: Drive Chain Tension

    General Maintenance 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 105: Hydraulic Brake Inspection

    MAINTENANCE General 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. This distance, called brake lever reserve (A), 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 106: Brake Components

    5. Brake Pad Material (Replace when thickness is less than 1/16″). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as described on page 102, the machine should be returned to an authorized Polaris dealer for inspection and adjustment.

  • Page 107: Brake Fluid

    Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately. Use only Polaris DOT 3 high temperature brake fluid. See page 132 for the part numbers of Polaris products. On some models, the brake fluid level can be seen through a plastic sight glass in the brake reservoir.

  • Page 108: Bleeding The Hydraulic Brake System

    General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death.
  • Page 109 MAINTENANCE General Maintenance Mechanical Brake Lever Travel WARNING Improper brake adjustment could result in brake failure and lead to serious injury or death. See your dealer for brake service. Frequently inspect the brake lever reserve (A), which is the clearance between the lever and the brake block.

  • Page 110: Headlight Adjustment

    General Maintenance 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 111 MAINTENANCE General Maintenance Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer. 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.

  • Page 112: Taillight Replacement

    General Maintenance Taillight Replacement 1. Remove the rear storage cover (A) if equipped. 2. Depending on your model, remove the screws (B) securing either the taillight housing (C) or the lens cover (D). 3. Remove and replace the bulb (E). 4.

  • Page 113: Clutch System

    CAUTION The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated. Do not lubricate clutch bushings. Periodically inspect the clutch sheaves for damage, wear, or belt residue.

  • Page 114: Drive Belt Condition

    General Maintenance 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. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature.

  • Page 115: Drive Belt Installation

    MAINTENANCE General Maintenance Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack (A). To ensure satisfactory belt NOTE: life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them.

  • Page 116: Drive Belt Adjustment

    B. This measurement should be 1 1/4”. Drive Belt Adjustment Polaris Standard Reverse Clutch Belt deflection can be adjusted without removing the clutch from the jackshaft. 1. Pull the belt into the driven clutch to slightly open the sheaves.

  • Page 117: Torque Stop

    MAINTENANCE General Maintenance Torque Stop If your snowmobile is equipped with an engine torque stop (1), periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be a minimum of .010″ to a maximum of .030″ from the engine case (2).

  • Page 118: Tool Kit

    6. Flat Screwdriver 7. Box End Wrench Always keep the tool kit with the snowmobile. If necessary, a replacement tool kit may be purchased from your Polaris dealer. Chain Tension Maintain the proper chain tension as outlined on page 101.

  • Page 119: Fall Tune-Up

    Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Maintenance Items 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 120: Track Lubrication

    Track Maintenance Track Inspection WARNING 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 121: Track Tension

    MAINTENANCE Track Maintenance WARNING Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment is critical for proper handling.

  • Page 122: Track Tension Data

    Track Maintenance Track Tension Data Suspension Edge 136 10 lbs. (4.54 kg) (Indy 340 Touring) Edge Touring 10 lbs. (4.54 kg) ETS ACE 10 lbs. (4.54 kg) WideTrak 10 lbs. (4.54 kg) Track Alignment Periodically check that the track is centered and running evenly on the slide rails.

  • Page 123: Steering System

    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 124 MAINTENANCE Steering System 10″ 10″ Edge IFS 10″ 10″ WideTrak...

  • Page 125: Steering Inspection And Adjustment

    MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check fasteners and tighten if necessary. Specific fasteners that should be checked are marked with a in the following illustrations. All Steering Except CRC Edge IFS Steering System...

  • Page 126: Ski Skags

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

  • Page 127: 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″ is reached (3/8″ on WideTrak models). See your dealer for Hi-fax replacement. If excessive Hi-fax wear occurs due to poor snow conditions, additional wheel kits are available from your dealer.

  • Page 128: Cleaning And Preservation

    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 suspension mounting bolts for tightness.

  • Page 129: Controls And Linkage

    See page 132. Always add Premium Carbon Clean or a fuel conditioner/stabilizer to the fuel tank. See page 132 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 130: Electrical Connections

    Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. See page 132 for the part numbers of Polaris products. Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts.

  • Page 131: Transporting The Snowmobile

    MAINTENANCE 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.

  • Page 132: Battery Fluid

    Battery Battery Fluid WARNING Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immediate medical attention. KEEP OUT OF REACH OF CHILDREN. EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk.

  • Page 133: Battery Removal

    MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When cleaning is necessary, remove the corrosion with a stiff wire brush. Wash terminals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry with clean shop towels.

  • Page 134: Battery Installation

    Battery Battery Installation WARNING 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 negative cable last to avoid the possibility of explosion.

  • Page 135: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricants 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.)

  • Page 136: 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 tion or load variations Driven clutch malfunction Harsh drive Drive belt worn or...
  • Page 137 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 138 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 139: Suspension Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Edge 136 Suspension (Indy 340 Touring) Problem Solution (perform only one change at a time) Rear suspension - Increase torsion spring preload. bottoms too easily - Increase rear track compression damping by turning screw on rear track shock clockwise (factory position full soft). - Increase torsion spring wire diameter.
  • Page 140 Suspension Troubleshooting Edge Touring Suspension (ETS) and ETS ACE Problem Solution (perform only one change at a time) Rear suspension - Adjust RCA forward (see setup decal under hood). bottoms too easily - Adjust coil over spring on front track shock to increase preload - 1”...

  • Page 141: Belt Troubleshooting

    TROUBLESHOOTING 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 en- gagement Belt Wear/Burn Diagnosis...

  • Page 142: 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 143: 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 144: 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 145 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 146 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 147 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 148: Technology (Det)

    Accessories ....Air Box ......Air Pollution .

  • Page 149: Index

    Passenger Seat PERC ......Plug Cleaning POLARIS PRODUCTS Powder Snow Operation Pre-Ride Checklist . . .
  • Page 150 Shock, Indy Select Rear, Edge 136 Signal words ..... . Skag Replacement ....Ski Alignment .

This manual is also suitable for:

Widetrak2005 touring2005 widetrak2005 edge touring

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