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Polaris FST IQ Touring Owner's Manual

Polaris 2010 snowmobile owner's manual
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  • Page 2 Pantone 425C For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922571 Rev 01 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 • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
  • Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 6: Table Of Contents

    Polaris Products..... . . 141 Troubleshooting ..... . . 142 Warranty .

  • Page 8: Introduction

    INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations.

  • 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 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 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 sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
  • Page 12 Always check major and vital safety components before every ride. All Polaris snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from opera- tion with any modifications, especially those that increase speed or power. DO NOT MODIFY YOUR MACHINE.

  • Page 13: Operator Safety

    SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. WARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track.

  • Page 14: Survival Preparation

    Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.

  • Page 15: Eye Protection

    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 16: Rider Capacity

    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 17: Disabled Operators

    SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. WARNING! Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Do not allow disabled persons to operate this vehicle.

  • Page 18: Excessive Speed

    SAFETY Operator Safety Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile opera- tion and speed limits.

  • Page 19: 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 20 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 21: Driving Downhill

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

  • Page 22: Driving On Slippery Surfaces

    SAFETY Operator Safety Driving on Slippery Surfaces WARNING! Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard- packed snow reduces steering and braking control, which may result in loss of control and serious injury or death.

  • Page 23: Drive Belt

    SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. CAUTION! Operation of the engine with the belt removed may result in personal injury or damage to the engine.

  • Page 24: Operating In Deep Snow

    SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile. NOTICE: Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine.

  • Page 25: Driving Responsibly

    Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile condi- tions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won’t do under various conditions. Even seasoned driv- ers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.
  • Page 26 Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WIND CHILL CHART (°F) Wind Speed Calm Frostbite in >> 30 min. WIND CHILL CHART (°C) Wind Speed Calm -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 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69...

  • Page 27: 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 28: Passenger Warning

    Safety Decals and Locations “No Passenger” Warning Snowmobiles designed for a single rider only have a warning decal on the left console: WARNING This vehicle is designed for operator only. “NO PASSENGER” Passenger Warning Snowmobiles designed for an operator and one passenger have a warning decal on the left console.

  • Page 29: Reverse Warning

    SAFETY Safety Decals and Locations Reverse Warning Reverse Warning Polaris snowmobiles equipped with electric reverse and will have this decal on the console: WARNING Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always: •...

  • Page 30: Operation Warning

    Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all Polaris snowmobiles: 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.

  • Page 31: Features

    FEATURES 1. Nosepan 2. Skis 3. Front Bumper (do not use for pulling or dragging the snowmobile) 4. Hood 5. Headlight 6. Windshield 7. Operator Seat 8. Passenger Seat 9. Backrest 10. Passenger Grab Handle 11. Cargo Bag 12. Grab Handle Heater Switch 13.

  • Page 32: Features

    1. MFD Display 2. Mirrors 3. Rider Selectt 4. Fuel Filler Cap 5. Handlebar 6. Hood Hold Down Straps 7. Handlebar Grip Warmer Switch 8. Thumbwarmer Switch 9. Electronic Reverse Button 10. MFD Control 11. Headlight Dimmer Switch 12. Parking Brake Lock 13.
  • Page 33 FEATURES Backrest The backrest is adjustable for either operator or passenger use. 1. Loosen the upper adjustment knobs to raise or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest for- ward for operator use or rear- ward for passenger use.

  • Page 34: Features

    Cargo Bag The cargo bag is secured to the rear of the tunnel with straps. The cargo bag and the passenger seat are removable to provide open storage for transporting larger items. The maximum weight capacity for the cargo area is 30 lbs. (14 kg).

  • Page 35: Features

    FEATURES Passenger Grab Handle On some models the position of the passenger grab handles can be adjusted for rider preference. 1. Unscrew and remove the knob assemblies that secure the grab handles. 2. Reposition the grab handles to one of the three available posi- tions on the grab handle tube between the operator seat and the passenger seat.

  • Page 36: Features

    FEATURES 12-Volt DC Outlet If equipped, use the outlet to power a global positioning sensor (GPS), heated helmet shield, utility light, cell phone or other accessories. The 12-volt DC outlet is installed in the recoil pocket next to the right hood hold-down. If you install an accessory outlet on your model, always install it in the recoil pocket.

  • Page 37: Features

    WARNING! If your snowmobile has five adjustment positions, do not remove the RIDER SELECT lockout. Your Polaris snowmobile has been engineered for this range of adjustability. Removing this lockout and using RIDER SELECT position 6 or 7 will result in the handlebars and brake lever contacting other components and interfering with steering and braking.

  • Page 38: Features

    RIDER SELECT Adjustable Steering System Choosing the Best RIDER SELECT Position Position Riding Style Relaxed Trail Riding Rider weight is slightly behind the center of the snowmobile for comfortable and relaxed riding. General Trail Riding, Boondocking, Deep Snow Riding Rider weight is centered on the snowmo- bile, providing balance, comfort and con- trol for both novice and experienced riders.

  • Page 39: Features

    FEATURES RIDER SELECT Adjustable Steering System WARNING! Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system. 1.

  • Page 40: Features

    38 to identify the cause. If you are unable to determine the cause of an illuminated MIL, please see your Polaris dealer. Flashing MIL (Turbo) The MIL will flash if an error with the turbo boost regulation system is detected.

  • Page 41: Features

    FEATURES Engine Management System To protect the engine, the engine management system will limit engine RPM, vehicle speed or turbo boost (if equipped) if the following condi- tions are encountered. Under extreme overheating conditions, the sys- tem will also stop the engine entirely to prevent engine damage. Vehicle Speed is Limited Cause Reverse is selected...

  • Page 42: Features

    FEATURES Engine Management System The engine management system is programmed to alert the rider when coolant temperatures reach higher-than-normal levels. The system responds by taking the following sequential steps to alert the rider. 1. The High Temperature Indicator on the MFD will flash. To cool the engine, drive the snowmobile into soft snow so that it comes into contact with the heat exchangers on the snowmobile.

  • Page 43: Features

    FEATURES Knock Sensor (Turbo Models) A knock sensor monitors the engine and responds to detonation by auto- matically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance. Engine performance will be reduced if fuel with a lower octane than 91 is used.
  • Page 44 Instrumentation MFD Component Identification Item 1 Analog Gauge 2 Digital Gauge 3 Check Engine Indicator 4 High Temp Indicator 5 Brake Indicator 6 Reverse Indicator 7 High Beam Indicator Digital Display Identification Item RPM or Speed Altitude (if equipped) Service Interval Electrical System Voltage Level MAX - Maximum MPH/...

  • Page 45: Features

    FEATURES Instrumentation MFD Settings The MFD control switch allows you to set the MFD display to your pref- erences. The rocker switch has a MODE button (top) and a SET but- MODE ton (bottom). Specific instructions are outlined on the following pages. MFD settings can be made with the engine running or with the engine off.

  • Page 46: Features

    Instrumentation MFD Settings Speedometer/Tachometer The speedometer and tachometer can be viewed in either the analog or the digital display. If the analog display is set to show speedometer read- ings, the digital screen will automatically display the tachometer (option 1). If the analog is set to show the tachometer, the digital screen will show the speedometer (option 2).
  • Page 47 Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD pro- grams: Performance, Engine and History. Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycle through the program’s screens.

  • Page 48: Features

    FEATURES Instrumentation MFD Digital Display Programs Performance Program Trip Settings Trip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge. The fuel symbol and the last fuel bar on the MFD gauge (if equipped) will blink when the fuel level reaches 1/8 of a tank.

  • Page 49: Features

    FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting (if equipped) 1. Enter the Performance Program. 2. Press and release the SET button until the clock screen is active. 3. Press and hold the SET button for five seconds. 4.

  • Page 50: Hour Meter

    Instrumentation MFD Digital Display Programs Engine Program Press and release the MODE button until the engine program screen is active. The default display for this screen includes engine hours, electri- cal system voltage level, fuel level (if equipped) and either engine cool- ant temperature, air temperature (accessory) or altimeter (accessory).

  • Page 51: Features

    FEATURES Instrumentation MFD Digital Display Programs Engine Program Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. 1. Enter the Engine Program. Tip: Press and hold the MODE switch for ten sec- onds to switch between standard and metric units of measurement.

  • Page 52: Features

    Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active. This screen will always display electrical system voltage level and fuel level (if equipped). Press and release the SET button to cycle through the Maximum Vehicle Speed, Maximum Engine RPM and Service Interval Reminder screens.

  • Page 53: Features

    FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due.

  • Page 54: Features

    Instrumentation MFD Digital Display Programs History Program Service Interval Reminder To reset the reminder at a new interval: 1. Enter the History Program. 2. Press and release the SET button until the service interval screen is active. 3. Press and hold the SET button for five seconds, until the hours begin to flash.

  • Page 55: Features

    FEATURES Instrumentation MFD Battery Replacement Models equipped with the clock feature have a battery to power the clock. If the clock function of the MFD isn't working properly, replace the battery. Replace- ment batteries are available from your dealer. 1. Remove the plenum from the under- side of the hood.

  • Page 56: Features

    Instrumentation MFD Battery Replacement 5. Using needle-nose pliers, grasp the battery and rotate it so the lead- ing edge of the battery is raised away from the battery holder. Pull the battery out gently. Tip: The battery will not come out of the holder unless the leading edge of the battery is raised.

  • Page 57: The Perfect Fit

    THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 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 58: Front Shock Spring Preload

    Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris dealer for assistance before attempt- ing to adjust preload. Increasing the spring preload too much may adversely affect the han- dling of the snowmobile and the performance of the rear suspension.

  • Page 59: 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 The front spring rates can be adjusted by changing the nitrogen pressure.

  • Page 60: Suspension Performance Tips

    • In deep snow, a new rail slide will offer improved performance over a worn slide. It can also improve top speed. • Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. Tip: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.
  • Page 61 THE PERFECT FIT IQ Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the 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 62: Torsion Spring Preload

    Medium Firm Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of sus- pension coupling, these torque arms could move independently of each other. Rear suspension coupling links the movement of the front and rear torque arms to each other.
  • Page 63 THE PERFECT FIT IQ Rear Suspension Adjustments Front To Rear Coupling and the Front Rear Scissor Stop (FRSS) The front rear scissor stop (FRSS) couples the movement of the front torque arm with the rear torque arm and limits the amount of indepen- dence between the movement of the front torque arm and the rear torque arm.

  • Page 64: Weight Transfer During Acceleration

    IQ Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. To decrease weight transfer under acceleration (for improved corner- ing), rotate the RRSS to a higher position.

  • Page 65: Handlebar Adjustments

    Handlebar Adjustments Use the RIDER SELECT feature to adjust handlebar position. See page 34. Use the following steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts. 2.
  • Page 66 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: •...

  • Page 67: Traction Products

    Before equipping your snowmobile with traction products, be aware of the laws in your area pertaining to the use of traction products. Use only Polaris traction products on your snowmobile. Track warran- ties are void if track damage or failure results from improper or exces- sive stud installation or the use of non-Polaris traction products.

  • Page 68: Wear Strips

    Traction Products n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control.

  • Page 69: 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 Parking Brake Lock/Brake Lever/Brake System...
  • Page 70 PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death.

  • Page 71: Steering System

    PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed.

  • Page 72: Brake Lever Travel

    PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the 1/2" (1.3 cm) handgrip than 1/2" (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.

  • Page 73: Parking Brake Lock/Brake Lever/Brake System

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

  • Page 74: Track Inspection

    PRE-RIDE INSPECTIONS Before Starting the Engine n Track Inspection WARNING! Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle. WARNING! Use of traction products such as studs increases the possibility of track damage and/or failure.

  • Page 75: Suspension Inspection

    Before Starting the Engine n 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. Item Suspension mounting bolts Rear idler wheel bolts...

  • Page 76: Start The Engine And Check

    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. Lighting Check the headlight (high and low beam), taillight, and brake light.

  • Page 77: Tip-Over Inspections

    OFF position, then restart. WARNING! Operating a snowmobile with accident damage can result in serious injury or death. Do not operate the snowmobile if vehicle components have been damaged in a collision or tip-over. Have the snowmobile inspected by an authorized Polaris dealer.

  • Page 78: Operation

    Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. •...

  • Page 79: Break-In Period

    OPERATION Break-In Period The break-in period for your new Polaris snowmobile is the first 500 miles (800 km) of operation. No single action on your part is as impor- tant as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient per- formance and longer life for these components.

  • Page 80: Starting The Engine

    Starting the Engine 1. Turn the key to the ON position. NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 2.

  • Page 81: Emergency Starting

    OPERATION Emergency Starting If the battery is too weak to start the engine, and a battery charger is not available, the engine can be started using jumper cables and a charged battery from another vehicle. Carefully read and follow the instructions on the following pages.
  • Page 82 Emergency Starting 1. Always wear eye protection when jump starting your vehicle. 2. Keep bystanders away from the vehicles. 3. Perform the emergency starting procedure in a well-ventilated area. 4. Position the vehicles close enough for the jumper cables to reach easily between the batteries, but do not allow the vehicles to touch each other.
  • Page 83 16. If the engine still does not start, remove the jumper cables as out- lined in step 17 and transport the snowmobile to an authorized Polaris dealer for service. 17. Carefully remove the jumper cables in this order: A. Remove the negative end of the jumper cable from the snowmobile chassis.

  • Page 84: Fuel Level

    Do not allow the snowmobile to run out of fuel. Always refuel when the level is low. For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor- mance will be lost and fuel economy will decrease.

  • Page 85: Track Warm-Up

    Track Warm-Up WARNING A loose track or flying debris could cause serious injury or death. Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle dur- ing warm-up or when the track is free-hanging.
  • Page 86 Track Warm-Up Follow these steps to ensure proper warm-up of the engine, drive train and track. 1. Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper. The track should be approximately 4" (10 cm) off the ground.
  • Page 87 If a defective switch is detected by the self diagnostics system, the MIL will illuminate. Take your snowmobile to an authorized Polaris dealer for diagnosis and repair if the MIL is illu- minated. Stop Switch...

  • Page 88: Throttle Lever

    Tip: Excessive freeplay in the throttle cable may cause the safety switch to acti- vate, preventing the engine from starting. If this occurs, return the snowmo- bile to an authorized Polaris dealer for service. Turbo Noise (Turbo models) Under some conditions, when the throttle lever is released the boost pressure dump valve will release pressure, and you may hear the sound of escaping air.
  • Page 89 OPERATION Electronic Reverse (PERC 4t) Electronic reverse will activate only when the vehicle is stopped and engine speed is below 2500 RPM. Maximum vehicle speed when oper- ating in reverse will be approximately 12 MPH (19 km/h). WARNING! Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death.

  • Page 90: Ignition Switch

    Electronic Reverse (PERC 4t) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button for one second and release. The light on the instrument panel will shut off. 3. Apply the throttle slowly to make sure the transmission is in for- ward.

  • Page 91: Daily Storage

    OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and sup- port it at the rear with an appropriate track stand. The track should be suspended approximately 4" (10 cm) off the ground. Remove the key and cover the snowmobile.

  • Page 92: Maintenance

    Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsi- ble for ensuring that the specified maintenance is performed. Polaris recommends that you contact an authorized Polaris dealer to perform...
  • Page 93 Polaris dealer for service. Polaris does not recommend tipping the snowmobile onto it's side for service. In the event of a tip-over or rollover, check the oil level before operating the snowmobile. Inspect the foam oil breather element any time the snowmobile has been tipped onto its left side.
  • Page 94 Periodic Maintenance Interval Table O = Perform Service X = Replace Item Engine Stop Switch Ignition Switch Throttle Safety Switch Taillight Brakelight Headlight Skags (Wear Bars) Fluid Leaks Parking Brake Brake Lever Coolant Brake fluid Hood Latches Seat Latches Rail Slide Foam Oil Breather Element Front and Rear Sus-...

  • Page 95: Gearcase Oil Level

    MAINTENANCE Periodic Maintenance Interval Table O = Perform Service X = Replace Item Track Alignment Coolant Hoses Heat Exchangers Fuel Lines Battery Track Tension Handlebars Drive Chain Gearcase Oil Rear Suspension Bearings Throttle Cable Clutches Drive Belt Air Filter (Turbo) Oil Change Fuel Filter Instructions...
  • Page 96 Periodic Maintenance Interval Table O = Perform Service X = Replace Item Engine Mounts Spark Plugs Exhaust System Hoses Brake Pads/Disc Fuel Vent Lines Ski Toe Cooling Fins/Shroud Valve Lash Cooling System Fuel Filter Rear Suspension Shock Oil Instructions (see referenced pages) Inspect, replace if worn or damaged 107 Inspect condition/gap,...

  • Page 97: Engine Oil Level

    Polaris 4-cycle snowmobile engines. It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. Oil may need to be changed more frequently if Polaris PS-4 oil is not used. Follow the manufacturer's recommendations for ambient tempera- ture operation.
  • Page 98 Engine Oil n Oil Level Check The oil level in the oil bottle may drain below the level of the dipstick if the engine has not run for more than a week. If you're not sure if there is oil in the system, you must first check to make sure oil is in the system before checking the oil level.
  • Page 99 MAINTENANCE Engine Oil n Oil Level Check 8. Maintain the oil level in the safe operating range, between the upper and lower marks on the dip- stick. If the level is low, add the recommended oil in small increments, about 2 ounces (60 ml), and recheck the level. Tip: If the level is low, or when changing the oil, add only enough oil to bring the level to the bottom of the safe operating range on the dipstick.

  • Page 100: Oil In System Check

    5 seconds, stop the engine, and recheck for the presence of oil. 7. If no oil is present on the dipstick, check the oil system for leaks and proper operation or see your Polaris dealer. MAINTENANCE...

  • Page 101: Oil Change

    Table beginning on page 91. Clean the foam oil breather element with each engine oil change. See page 102. Always use the recommended oil. See page 94, or see your Polaris dealer about oil change kits, which contain a new filter and the recom- mended oil.
  • Page 102 Engine Oil Oil Change 5. Remove the oil return hose from the oil tank. Have an assistant place the end of the hose into a drain pan. 6. Disconnect the 2-pin WHITE/RED and GREEN/WHITE starter motor solenoid control switch harness connector located near the battery.
  • Page 103 Engine Oil Oil Change 18. Remove the oil filter cap, then remove the oil filter. Inspect the o- ring and replace it if it's worn or damaged. 19. Install a new filter, then reinstall the cap. Tighten the cap to 18.5 ft. lbs.
  • Page 104 Engine Oil Oil Change 26. Add additional oil to bring the level slightly above the lower mark (in the safe operating range) on the dipstick. See the chart for approximate amounts to add at this step. DO NOT OVERFILL. MODEL All FST Tip: Check the oil level often during the fill procedure to avoid overfilling.

  • Page 105: Foam Oil Breather Element

    Foam Oil Breather Element The foam oil breather element absorbs small amounts of liquid to pro- tect sensors within the intake system from damage due to oil ingestion. Check the element before each ride. Clean or replace the breather ele- ment at each engine oil change.

  • Page 106: Throttle Cable

    MAINTENANCE Lubrication Driveshaft Bearing Fitting Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lightly with grease or oil.

  • Page 107: Rear Suspension

    MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 91 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

  • Page 108: Gearcase Oil

    Periodic Maintenance Table beginning on page Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 141 for the part numbers of Polaris products. The dipstick is located on the lower front side of the gearcase. Maintain...

  • Page 109: Gearcase Oil Change

    Gearcase Oil Change The drain plug is located on the bottom of the gearcase. Polaris does not recommend tipping the snowmobile onto it's side for service. Any time the snowmobile is tipped onto it's left side, always check the oil level and clean the foam oil breather element.

  • Page 110: 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. NOTICE: Using non-recommended spark plugs can result in serious engine damage.
  • Page 111 MAINTENANCE Spark Plugs Normal Spark 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. Tip: The tip should not be white.

  • Page 112: Fuel Filter

    All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump. Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 91. Fuel Lines Inspect the fuel lines regularly for signs of deterioration or damage.

  • Page 113: Alternator Belt Inspection

    Alternator Belt Inspection Inspect the alternator belt condition and tension before each ride. 1. Stop the engine. 2. Open the hood. 3. Inspect the belt for wear, cracks or other damage. If the belt is worn or damaged, install a new belt. 4.

  • Page 114: Exhaust System

    4. Replace any damaged or missing components. 5. Clean the plastic surfaces next to the muffler with aerosol Carbure- tor and Throttle Body Cleaner. See page 141 for the part numbers of Polaris products. 6. Close the hood.

  • Page 115: Cooling System

    Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/ 40% water mixture. See page 141 for the part numbers of Polaris prod- ucts. Tip: 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 116: Coolant Level

    Cooling System n Coolant Level The engine coolant level is controlled by the recovery system. The recovery system components are: • Coolant reservoir bottle • Filler neck • Pressure cap • Coolant overflow tank • Connecting hoses Always maintain the coolant level at the “COLD FILL”...
  • Page 117 Cooling System Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine cool- ant temperature becomes too hot for safe continued operation of the engine. Stop the snowmobile and allow the engine to cool. Place snow on the coolers to help cool the engine.

  • Page 118: Flushing The Cooling System

    To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh mix- ture of antifreeze and distilled water should be added. Have your Polaris dealer perform this service.
  • Page 119 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. 1. Read the entire coolant bleed procedure before beginning. 2.
  • Page 120 Cooling System Bleeding the Cooling System 8. While observing the coolant reservoir bottle and making sure the coolant level is visible, observe the engine temperature in the digital display. The temperature should rise steadily, indicating that the sys- tem is bleeding properly. 9.

  • Page 121: 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 122: Brake Components

    1/16" (1.5 mm). Excessive Lever Travel Hydraulic brakes are self- adjusting, but if excessive brake pad clearance develops bring the snowmobile to an authorized Polaris dealer for inspection and adjustment. Bleed Screw Brake Disc Brake Line Brake Caliper...

  • Page 123: Brake Fluid

    NOTICE: Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately. Replace brake fluid at least every two Sight Glass years with Polaris DOT 4 high tem- perature brake fluid. See page 141 for the part numbers of Polaris products. The brake fluid level can be seen...

  • Page 124: 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. WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever.

  • Page 125: Removing Halogen Bulbs

    Lights Removing Halogen Bulbs Tip: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a resi- due, 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. 1.

  • Page 126: Electrical System

    Electrical System RELAY LABEL START SOLENOID RELAY CHASSIS RELAY RELAY IGNITION RELAY FUEL PUMP RELAY FAN RELAY FUSE LABEL Ground side of start solenoid SPARE 20A None ACCESSORY Accessory plugs EMERGENCY SPARE 30A High beams Low beams Handwarmers CHASSIS Thumbwarmer Tail lamp Brake lamp Alternator coils...

  • Page 127: Clutch System

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

  • Page 128: 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 129: Drive Belt Removal

    MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. 1. Stop the engine after operating in a forward motion. Tip: For easier accessibility, make sure the clutch tool access hole is visible between the 11:00 and 2:00 positions of the clutch sheave.

  • Page 130: Drive Belt Installation

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

  • Page 131: Track Replacement

    Track Replacement When replacing the track, always install a track having the lug size rec- ommended for your model. See your Polaris dealer. NOTICE: Installing tracks with larger lugs on snowmobiles equipped with coolers will result in damage to the cooler or tunnel. Always install a track having the lug size recommended for your model.

  • Page 132: Track Lubrication

    Track Lubrication WARNING! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication.

  • Page 133: Track Tension

    MAINTENANCE Track Tension 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 adjustment is critical for proper handling. Always maintain cor- rect tension and alignment.
  • Page 134 Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic rail slide. If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7. Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the track.

  • Page 135: Track Alignment

    35 ft. lbs. (47.5 Nm). 5. Repeat steps 2 and 3 to verify proper alignment. Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum per- missible slide thickness.

  • Page 136: Steering Inspection And Adjustment

    MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride. Tighten any loose fasteners.

  • Page 137: Ski Alignment

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

  • Page 138: Skags (Wear Bars)

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

  • Page 139: Battery Removal

    MAINTENANCE Battery WARNING! Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.

  • Page 140: Battery Storage

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. Tip: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge.
  • Page 141 MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 or greater.

  • Page 142: 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 141 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 143: Electrical Connections

    Extended Storage Engine Protection Fogging the engine is not recommended for this model. NOTICE: Fogging the engine improperly can result in damage to the sensors. Fogging is not recommended. Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts.

  • Page 144: Polaris Products

    Part No. Engine Lubricants 2874865 Performance Synthetic 4-Stroke (PS-4) Oil (qt.) 2874866 Performance Synthetic 4-Stroke (PS-4) Oil (gal.) 2876244 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (qt.) 2876245 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (gal.) 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097...

  • Page 145: Troubleshooting

    Engine and Drive Train Troubleshooting Engine Speed, RPM or Boost is Limited Probable Cause Engine Management System RPM Reduction Mode is activated Jammed clutch Jammed track Jammed or broken chaincase sprocket or chain Mechanical failure Engine Doesn't Turn Over Probable Cause Low battery voltage Loose battery connections Loose solenoid connections...
  • Page 146 Engine and Drive Train Troubleshooting Engine Turns Over, Fails to Start Probable Cause Out of fuel Water is present in fuel Old or non-recommended fuel Fouled or defective spark plugs No spark to spark plug Water or fuel in crankcase Clogged fuel filter Low battery voltage Poor engine compression...
  • Page 147 Engine and Drive Train Troubleshooting Engine Runs Irregularly, Stops or Loses Power Probable Cause Engine Management System RPM Reduction Mode is activated Low battery voltage Water is present in fuel Poor quality or low octane fuel Loose ignition connections Incorrect spark plug gap or heat range Fouled or defective spark plug Kinked or plugged fuel vent line Clogged air filter...

  • Page 148: Engine Overheating

    Engine and Drive Train Troubleshooting Engine Overheating Probable Cause Inadequate snow conditions Low coolant Restricted air flow to radiator Harsh Drive Clutch Engagement Probable Cause Worn drive belt Excessive belt/sheave clearance Drive Belt Turns Over Probable Cause Incorrect belt Incorrect clutch alignment Broken or loose engine mount Drive System Noise Probable Cause...
  • Page 149 TROUBLESHOOTING IQ Comfort Suspension Troubleshooting Problem Rear suspension bot- toms too easily Rides too stiff in rear Snowmobile darts from side to side Front end pushes Steering is heavy Solution • Adjust torsion spring preload to achieve proper static sag (see page 58).

  • Page 150: Drive Belt Wear/Burn

    Drive Belt Wear/Burn Cause Driving at low Drive at higher RPM. Gear the machine down. Check belt deflection. Insufficient warm- Warm the engine at least five minutes. Take the drive belt off the snowmobile in extremely cold weather and warm it up. Break snowmobile loose from the snow.

  • Page 151: Warranty

    Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you. When contacting us about parts, service, or warranty, always provide the following information: 1.
  • Page 152 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...

  • Page 153: 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 154 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 155 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 156 • 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 157 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 158 This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S.
  • Page 159 Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that you use only Pure Polaris parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 160: Maintenance Log

    Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) 150 mi. (240 km) 500 mi.
  • Page 161 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 162 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 163: Index

    INDEX Access Panel, Radiator Compartment 30 Accessories ....63 Adjustable Steering System..34-36 Air Filter (Turbo)....110 Alternator Belt Inspection .
  • Page 164 Passenger Warning ....25 Polaris Products ....141 Pre-Ride Checklist ... 66, 74 Pressure Cap Warning .
  • Page 165 INDEX Springs, Front ....56 Starting the Engine ... . . 77 Starting, Emergency ..78-80 Steering Inspection .

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