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Troubleshooting
Related Manuals for Polaris Widetrak LX
Summary of Contents for Polaris Widetrak LX
- 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. Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...
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Page 6: Table Of Contents
Polaris Products..... . . 105 Suspension Troubleshooting ... . 106 Troubleshooting . -
Page 7: 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. When teaching inexperienced operators to ride, set up a predetermined course for practice. -
Page 8: Preservation Of The Environment
Polaris snowmobiles are engineered to conform to these SAE standards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others. -
Page 9: 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, so if both keys are lost, the ignition switch must be replaced. -
Page 10: 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 11: 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 12 Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Stay Clear of Engine Never attempt adjustments with the engine running. Turn off the igni- tion, raise the hood, make the adjustment, secure shields and guards, secure the hood, and then restart the engine to check its operation.
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Page 13: 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 condi- tions you may encounter. -
Page 14: Riding Apparel
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 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. -
Page 16: Excessive Speed
Excessive Speed High speed driving, especially at night, could result in serious personal injury or death. Always reduce speed when driving at night or in inclement weather. Observe all state and local laws governing snowmobile operation. They’ve been established for your protection. Always be alert and pay attention to the trail ahead. -
Page 17: Driver Awareness
SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. - Page 18 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.
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Page 19: Ice And Snow Build-Up
SAFETY Operator Safety Ice and Snow Build-up Ice and snow build-up may interfere with the steering of your machine, result- ing in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. -
Page 20: Driving In Hilly Terrain
Operator Safety Driving in Hilly Terrain Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over. -
Page 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
SAFETY Operator Safety Intake Silencer Do not operate the engine with the intake silencer or filter removed. Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. -
Page 23: Inadequate Snow Conditions
Operator Safety Inadequate Snow Conditions Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. 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 machine. -
Page 24: 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 machine and with what it will and won’t do under various conditions. Even seasoned driv- ers should spend some time getting the feel for a machine before attempting ambitious maneuvers. - Page 25 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...
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Page 26: 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 27: Safety Decals And Locations
Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. Reverse Warning Polaris Widetrak snowmobile is equipped with standard reverse. The reverse warning decal is located above the instrument hous- ing. -
Page 28: 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 29: Features And Controls
FEATURES AND CONTROLS GeneralRepresentation 1. Fuel Filler Cap (may include a fuel gauge) 2. Ignition Switch 3. Brake Lever 4. Speedometer (may include indicator/warning lights) 5. Reverse Indicator 6. Mountain Bar 7. Engine Stop Switch (see page 54) 8. Throttle Control 9. -
Page 30: Fuel Valve
Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on this page. Not all models come with these features. Refer to your Owner’s Manual Supplement. NOTE: Accessories are available from your Polaris dealer. 1. Headlight Dimmer Switch 2. - Page 31 FEATURES AND CONTROLS 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Operator Seat 6. Passenger Hand Hold Strap 7. Cargo Rack 8. Taillights 9. Snow Flap 10. Track 11. Suspension 12. Trailing Arm 13. Nosepan 14. Front Bumper (do not use for pulling or dragging the snowmobile) 15.
- Page 32 Backrest The backrest is adjust- able 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 back- rest forward for operator use or rearward for pas- senger use.
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Page 33: The Perfect Fit
THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles (240 km) and re- grease all suspension parts before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. -
Page 34: Shock Components
Front Suspension Adjustments Always verify ski alignment before making adjustments to the IFS. See page 94 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spring is set is called spring preload. For the best ride, the spring preload should be set as low as possible to use the full travel of the ski shock, with occasional light bottoming. -
Page 35: Shock Spring Preload
Special tools are required to adjust front springs. If you feel that your front suspension needs adjustment see your Polaris dealer for more information. Front Shock Washers... -
Page 36: Suspension Performance Tips
Bogie wheel kits are available from your dealer. • Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components. - Page 37 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.
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Page 38: Handlebar Adjustments
Handlebar Adjustments Standard Handlebar Follow these steps to adjust handlebar angle at the handlebar block. 1. Remove the mountain bar by removing nuts. 2. Using a 7/16-inch wrench, loosen the four nuts on the bottom of the adjuster block (turn the handlebar either left or right for access to the rear nuts). -
Page 39: Traction Products
THE PERFECT FIT Traction Products nCarbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Inspect skags frequently. - Page 40 Accessories Polaris offers a wide range of accessories for your snowmobile. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: •...
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Page 41: 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 ( locate the pre-ride inspection items Drive Belt Condition Steering System Recoil Rope Parking Brake Lock/Brake Lever/... -
Page 42: Before Starting The Engine
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. Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death. -
Page 43: Hydraulic Brakes
See pages 78-79 or see your dealer for service. Replace brake fluid at least every two years. We recommend the use of Polaris DOT 4 high temperature brake fluid. See page 105 for the part numbers of Polaris products. -
Page 44: Parking Brake Lever Lock
Before Starting the Engine n Parking Brake Lever Lock Your snowmobile may have a parking brake lever lock located over the brake lever. Use the brake lever lock only when you want the machine to remain sta- tionary; for example, when parked on an incline for a period of five minutes or less. - Page 45 Before Starting the Engine n Steering System Manually turn the skis completely to the right and to the left. If any dif- ficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated.
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Page 46: Hood Latches
Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your Polaris dealer for replacement. n Transmission Make sure the transmission is not in reverse before starting the engine... - Page 47 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. Lighting Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating.
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Page 48: Starting The Engine
Starting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the fuel valve on. See page 27. -
Page 49: Operation
Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injec- tion system, will assure proper engine break-in. -
Page 50: Oil Injection System
This snowmobile is equipped with a variable exhaust system (VES). Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends the use of VES II 2 Cycle Oil for this engine. See page 105 for the part numbers of Polaris products. - Page 51 OPERATION Track Warm-Up 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 52 Operate this vehicle only outdoors or in well-ventilated areas. Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane gasoline available, so we encourage the use of premium fuel when possible.
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Page 53: 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 54: Low Oil Indicator Light
They may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All Polaris oils are compatible with each other. Always maintain the oil level above the tank’s low level line. This is especially important when the machine is operated in mountainous ter- rain. -
Page 55: Low Oil Level
U.S. quart of recommended oil to the tank. See page 47 for oil recommendations. The Polaris oil cap on the oil tank may be vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts. -
Page 56: Jetting Guidelines
Carburetion Jetting Guidelines Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. RMK carburetors are preset to operate at altitudes of 6000-8000 feet (1800-2400 m) above sea level (see page 74 for more information). -
Page 57: Engine Stop Switch
OPERATION Engine Stop Switch Push down on the engine stop switch to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position. - Page 58 When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the machine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealer for service as soon as possible. WARNING OPERATION...
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Page 59: Emergency Stopping
OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 54 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch Excessive or repetitive use of brakes for high speed stops will cause an over- heated brake system. -
Page 60: Emergency Starting
Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Snowmobiles equipped with electric start have a recoil for emergency starting. If the recoil starter system fails, an emergency start strap is provided in the kit. Reverse Operation Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. - Page 61 OPERATION Towing Do not use the front bumper to pull or drag the snowmobile. The front bumper is not designed for this type of use and may detach from the vehicle if force is applied. For your safety, do not attempt to using the tow hitch until you’ve read the following warnings and understand the proper hitch functions.
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Page 62: Maintenance
MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa- tion hangtag. -
Page 63: Emission Control Information
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 64 If you’re not familiar with safe service or adjustment procedures and the use of tools, or if you don’t feel comfort- able performing these tasks yourself, contact an authorized Polaris dealer for service. NOTICE: Hot components can cause damage to plastic. Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection.
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Page 65: Item See Page
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 66: Brake System
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 67: Auxiliary Shut-Off Switch
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 68: Rail Slide Condition
Periodic Maintenance Interval Table Item Rear Suspension Pivot Shafts Camber Alignment Radius Rod Bushings Handlebar Centering Track Alignment Track Tension Front Limiter Strap Rail Slide Condition Chaincase Oil Gearcase Oil I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace Page... - Page 69 All-Season Grease at 500 miles (800 km) and annually or every 1000 miles (1600 km) thereafter. A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmo- biles. See page 105 for the part numbers of Polaris products.
- Page 70 MAINTENANCE Lubrication Rear Suspension WideTrak Rear Suspension...
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Page 71: Throttle Cable
MAINTENANCE Lubrication Jackshaft Bearing The jackshaft bearing on your model may be equipped with a grease fit- ting, but this component is greased for life at the factory. Additional lubrication is not required. Driveshaft Bearing Inject grease into the fitting on the speedometer drive adaptor until grease purges from inside or outside the bearing seal (approximately two... -
Page 72: Gearcase Oil Level
Clean the magnetic plug (2) every 500 miles (800 km) and whenever checking or changing lubricant. NOTICE: Mixing brands or using non-recommended lubricants could result in excessive wear to chain, sprockets and bearings. Always use Polaris-recommended products for your vehicle. MAINTENANCE... -
Page 73: Spark Plugs
Owner’s Manual Supplement. • Spark plug torque is 18-22 ft. lbs. (24.4-29.8 Nm). • Always carry spare spark plugs in case of an emergency. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. - Page 74 Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. A hot exhaust system and engine can cause serious burns.
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Page 75: Intake Filter
Intake Filter The intake foam filter and screen limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter and screen periodically to remove any accumulation of snow. NOTICE: Operating the snowmobile with the intake filters removed may cause carburetor icing. - Page 76 Carburetor Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sedi- ment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination.
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Page 77: Carburetor Adjustments
It’s your dealer’s responsibility to make sure the correct main jet is installed. NOTICE: Operating the snowmobile with incorrect jetting can result in serious engine damage. Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly. -
Page 78: Oil Filter
Fuel Filter/Fuel Lines The fuel filter is located inside the fuel tank. This component requires no maintenance. Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fuel compounds may occur. Replace worn or damaged fuel lines promptly. -
Page 79: Exhaust System
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 80: Brake Components
Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 40. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approximately 1/16 inch/1.5 mm). A kit is available for replacing brake pads. -
Page 81: Brake Fluid
If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. We recommend the use of Polaris DOT 4 high temperature brake fluid. See page 105 for the part numbers of Polaris products. -
Page 82: Bleeding The Hydraulic Brake System
Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever. -
Page 83: Headlight Adjustment
Lights Headlight Adjustment The headlight may be adjusted for vertical aim using the following pro- cedure: 1. Place the snowmobile on a level surface with the headlight approxi- mately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall. -
Page 84: Headlight Bulb Replacement
Lights NOTE: Avoid touching a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol- moistened towel. Headlight Bulb Replacement 1. -
Page 85: 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 86 Drive Belt Condition Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor perfor- mance.
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Page 87: Drive Belt Removal
Clutch System Drive Belt Removal 1. Stop the engine after operating in a forward motion. 2. Turn the ignition key off. Wait for the engine to stop completely. 3. Lock the parking brake (if equipped). 4. Open the hood. 5. Remove the clutch guard retain- ing pin and open the clutch guard. -
Page 88: Drive Belt Installation
Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rota- tion by positioning the identification numbers so that you can read them. -
Page 89: Drive Belt Deflection
MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt (1) and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (32 mm). -
Page 90: Tool Kit
A tool kit is included with each machine for emergency and routine maintenance. Always keep the tool kit with the snowmobile. Chain Tension Maintain the proper chain tension as outlined on page 76. Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. -
Page 91: Track Inspection
MAINTENANCE Track Track Inspection Broken track rods are a serious safety hazard. They can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. -
Page 92: Track Lubrication
Track Track Lubrication 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 lit- tle or no snow for lubrication. -
Page 93: Track Tension
MAINTENANCE Track Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine run- ning. Track Tension Track adjustment is critical for proper handling. - Page 94 Track Track Tension f the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the locknuts. 7. Tighten or loosen the track adjusting screws as necessary to pro- vide equal adjustment on both sides of the track. 8.
- Page 95 MAINTENANCE Track n Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the machine with the track off the ground.
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Page 96: Steering Inspection
MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check fasteners and tighten if neces- sary. Specific fasteners that should be checked are marked with a the illustration. -
Page 97: Ski Alignment
Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski align- ment or camber adjustment. See your Polaris dealer. With the handlebars in a straight-ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt. -
Page 98: Ski Skags
Steering System n Ski Skags Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice. -
Page 99: Suspension Inspections
MAINTENANCE Suspension Maintenance n 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. Replace the rail slides if they are worn to the top of the groove at any point along their length. -
Page 100: Battery Fluid
Battery Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immedi- ate medical attention. KEEP OUT OF REACH OF CHILDREN. EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Call physician immedi- ately. -
Page 101: Battery Removal
MAINTENANCE Battery Battery Connections Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. -
Page 102: Battery Installation
Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. Attach the hold down strap. 3. -
Page 103: Battery Storage
Battery Battery Storage When your snowmobile is placed in storage for one month or more (in summer or in winter): • Remove the battery. • Charge it to the proper level. • Store it in a cool dry place. • Check and/or charge monthly. •... -
Page 104: Daily Storage
The track should be suspended approximately 4 inches (10 cm) off the ground. Remove the key and cover the machine. NOTE: Polaris has accessory covers and track stands available to fit all mod- els. See your dealer for more infor- mation. -
Page 105: Cleaning And Preservation
MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts. Wipe down remaining surfaces with a damp cloth. -
Page 106: Controls And Linkage
(BDC), the lowest position in the cylinder. On twin cyl- inder models, the opposite piston will be up. 5. Pour approximately two ounces of Polaris injector oil into the spark plug hole. 6. Wait one to two minutes and perform steps 3 to 5 on remaining cyl- inders. -
Page 107: 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 105 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 108: Polaris Products
Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT4 Brake Fluid (12 oz.) 2872893 Engine Degreaser (12 oz.) 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carb and Throttle Body Cleaner POLARIS PRODUCTS Description... -
Page 109: Suspension Troubleshooting
SUSPENSION TROUBLESHOOTING Problem Rear suspension bot- • Verify sag dimension (see page 91). Adjust torsion spring toms too easily Rear suspension • Check for binding suspension components and grease all rides too stiff • Verify sag dimension (see page 91). Adjust torsion spring •... -
Page 110: Troubleshooting
Belt Wear/Burn 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 engagement Belt Wear/Burn Diagnosis... - Page 111 TROUBLESHOOTING Engine Troubleshooting NOTE: 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 acceler- ation or load variations Driven clutch malfunction Harsh drive Drive belt worn or too clutch engage-...
- Page 112 Engine Troubleshooting Problem Probable Cause Noise in drive Broken drive clutch system components Bearing failure/ chain- case, 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 113 Check tank level and fill up with cor- rect fuel. • Ice in fuel line, filter, or pump. On the standard Polaris carburetor, the choke will not function with the throttle depressed. See second item under “Probable Cause” of “Engine contin- ually backfires”.
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Page 114: 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 115 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. Polaris warranty will aid in notifying the proper owner when a unit is recovered...
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Page 116: 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 117: 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 118 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 119 • 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 120 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 121 This snowmobile engine emissions limited warranty is in addition to the Polaris standard limited warranty for snowmobiles. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions- certified snowmobile engine is designed, built and equipped so it conforms with U.S.
- Page 122 Polaris dealer to perform any service that may be necessary for your snow- mobile. 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.
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Page 123: 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 124 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
- Page 125 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
- Page 126 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
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Page 127: Index
Accessories ....37 Air Box Warning ....23 Air Pollution . -
Page 128: Index
Periodic Maintenance Table ..62-65 Polaris Products ....105 Pre-Ride Checklist ....38 Pre-Ride Inspections . - Page 129 INDEX Throttle Lever ....39, 55 Throttle Safety Switch ..39, 54 Tool Kit ..... . 87 Torque Stop .