Polaris 550 Shift 136 Owner's Manual For Maintenance And Safety
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Polaris 550 Shift 136 Owner's Manual For Maintenance And Safety

Polaris 550 Shift 136 Owner's Manual For Maintenance And Safety

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PMS 419
550 IQ Shift
550 IQ Shift ES
550 Shift 136
550 Shift 136 ES
550 IQ LXT
Snowmobile Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris 550 Shift 136

  • Page 1 PMS 419 550 IQ Shift 550 IQ Shift ES 550 Shift 136 550 Shift 136 ES 550 IQ LXT Snowmobile Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 PMS 419 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. 9922858 Rev 01 Printed in USA *9922858...
  • Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polarisindustries.com for the latest news, new product introduc- tions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 6 THE WAY OUT IQ SHIFT Copyright 2010 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result between the actual vehicle and the information presented in this publi- cation.

  • Page 7: Table Of Contents

    POLARIS Products..... . 98 Troubleshooting ......99 Warranty .

  • Page 8: Introduction

    Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.
  • Page 9 POLARIS snowmobiles are engineered to conform to these SAE stan- dards. 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: 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 11 Always check major and vital safety components before every ride. All POLARIS snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.
  • Page 12 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 13 Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 14 SAFETY Operator Safety Survival Preparation For your safety, always ride in a group of other snowmobilers. Always tell someone where you're going and how long you expect to be gone. If it isn't possible to ride with others, and you must travel into remote areas, always carry survival equipment that's appropriate to the condi- tions you may encounter.
  • Page 15 SAFETY Operator Safety Rider Capacity Driving 1-Up - Some POLARIS snowmobiles are designed for a single rider only. A decal on the console of these models indicates single rider operation. Never carry a passenger on a single-rider snowmobile. Driving 2-Up - Some POLARIS snowmobiles are designed for up to two riders.
  • Page 16 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts.
  • Page 17 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • Take an avalanche class • Travel with experienced people • Travel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon.
  • Page 18 SAFETY Operator Safety Ice and Snow Build-up WARNING! Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering.
  • Page 19 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the machine and keep it from rolling freely downhill.
  • Page 20 SAFETY Operator Safety Driving in Hilly Terrain WARNING! Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly terrain.
  • Page 21 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. Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do not operate the engine with the intake silencer or filter removed.
  • Page 22 SAFETY Operator Safety Inadequate Snow Conditions WARNING! 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 23 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile condi- tions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the machine and with what it will and won't do under various conditions. Even seasoned driv- ers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
  • Page 24 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WINDCHILL CHART (_F) Wind Actual Thermometer Reading (_F) Speed -10 -15 -20 -25 -30 -35 -40 -45 Equivalent Temperature (_F) Calm -10 -15 -20 -25 -30 -35 -40 -45 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63...
  • Page 25 If any decal becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety decals are pro- vided by POLARIS at no charge. The part number is printed on the decal. Clutch Cover Warning...
  • Page 26 SAFETY Safety Decals and Locations Track Warning The track warning decal is on the rear of the tunnel: 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.
  • Page 27 SAFETY Safety Decals and Locations Reverse Warning The reverse warning decal is located on the upper 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 28 • To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, con- tact a POLARIS dealer for a replacement. • This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control.

  • Page 29: Features

    FEATURES 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Taillights 7. Rear Bumper 8. Snow Flap 9. Console Storage Compartment (if equipped) 10. Suspension 11. Track 12. Skis 13. Nosepan 14. Front Bumper (do not use for pulling or dragging the snowmobile) 15.
  • Page 30 FEATURES 1. Fuel Filler Cap/Dipstick 2. Recoil Starter Handle 3. Reverse Indicator 4. Headlight Adjuster 5. Speedometer 6. Engine Stop Switch 7. Choke Lever 8. Ignition Switch 9. Brake Lever 10. Parking Brake 11. Handlebar Grip Warmer Switch 12. Thumbwarmer Switch 13.
  • Page 31 FEATURES Fuel Valve The fuel valve is located under the hood. Turn the fuel valve off whenever the snowmobile is stored or parked. 1. Turn the valve clockwise to turn off the fuel supply. 2. Turn the valve counter-clockwise to turn on the fuel supply. Adjustable Headlights Adjust the headlight beam by moving the adjuster to the left or right.

  • Page 32: The Perfect Fit

    THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
  • Page 33 THE PERFECT FIT Front Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pres- sure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. To change front shock spring preload, grasp the spring and rotate it.
  • Page 34 Refer to the suspension setup label on your snowmobile, or see your POLARIS dealer for initial suspension setup information. Additional adjustments can be made after initial setup. Make adjustments to one area at a time so you can evaluate the change. For further assistance, see...
  • Page 35 Bogie wheel kits are available from your dealer. • 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 36 THE PERFECT FIT 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 37 THE PERFECT FIT IQ Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more effort.
  • Page 38 THE PERFECT FIT IQ Rear Suspension Adjustments Suspension Coupling On all POLARIS snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other.
  • Page 39 THE PERFECT FIT IQ Rear Suspension Adjustments Suspension Coupling Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen- dent movement between the rear torque and the front torque arm.
  • Page 40 THE PERFECT FIT IQ Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling HIGH weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. MEDIUM To decrease weight transfer under acceleration (for improved corner-...
  • Page 41 THE PERFECT FIT 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 42 THE PERFECT FIT Handlebar Adjustments When making handlebar adjustments, always be sure the handlebars, brake lever and throttle lever operate smoothly and do not contact the fuel tank, windshield or any other part of the vehicle when the handle- bars are turned fully to the left or right. Upper Bolts Lower...
  • Page 43 • Injury to self or others This applies, but is not limited to the following areas: brakes, clutches, fuel systems, and exhaust systems. Tip: Exhaust systems are critical safety areas that must use approved POLARIS parts. Please see your POLARIS dealer for service.

  • Page 44: 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 ref- erenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Item See Page Drive Belt Condition...
  • Page 45 PRE-RIDE INSPECTIONS Before Starting the Engine WARNING! Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable snowmobiling experience.
  • Page 46 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 (1.3 cm) handgrip than 1/2I (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.
  • Page 47 PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1.

  • Page 48: Steering System

    PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System 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. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.

  • Page 49: Recoil Rope

    Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your POLARIS dealer for replacement. n Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time.

  • Page 50: Ignition Switch

    PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without check- ing all components to be sure of proper operation. See Before Starting the Engine beginning on page 41. Engine Stop Switch Check the auxiliary shut-off switch for proper operation.

  • Page 51: Operation

    OPERATION 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 52 Premix the first tank of fuel 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 53 Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. Oils 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. Drive Belt Break-In The break-in period for a new drive belt is 30 miles (48 km).
  • Page 54 OPERATION Track Warm-Up WARNING! A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging.
  • Page 55 OPERATION Fuel 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 56 Never use deicers or additives containing methanol. POLARIS also recommends the use of Carbon Clean Plus. See page 98 for the part numbers of POLARIS products. If you use oxygenated fuel containing ethanol, additional alcohol deic- ers or water absorbing additives should not be used.
  • Page 57 Always maintain a visible level of oil in the tank. If oil is not visible, continued operation may cause serious engine damage. See page 49 for oil recommendations. The POLARIS oil cap on the oil bottle is vented to allow proper oil flow. See your POLARIS dealer for recommended replacement parts.
  • Page 58 Either condition may be caused by improper carburetor adjustment. WARNING! Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage. Always have your POLARIS dealer perform any carburetor adjustments.
  • Page 59 OPERATION Carburetion Jetting Guidelines Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. The carburetors are calibrated for an altitude of 0-2000 ft.
  • Page 60 OPERATION Engine Stop Switch Push down on the engine stop switch (H) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restart- ing. Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.
  • Page 61 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 possi- ble.
  • Page 62 OPERATION Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. If your machine is running at an altitude of over 6000 feet, adjust the igni- tion setting as described on page 59. Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse Tip: The engine will activate a misfire mode and begin to stutter after 45 sec- onds in reverse.
  • Page 63 OPERATION Electronic Reverse (PERCt) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear. 3. Push the yellow reverse button on the left-hand control for one sec- ond, then release. The engine will automatically reduce RPM and start a reverse rotation.
  • Page 64 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 use a tow hitch until you've read the following warnings and understand the proper hitch functions.

  • Page 65: 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 any service that may be necessary.
  • Page 66 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 snowmo- bile on its side for service or inspection.
  • Page 67 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 Frequency Page 150 mi.

  • Page 68: Taillight/Brakelight/Headlight

    MAINTENANCE Periodic Maintenance Interval Table Item Frequency Page 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brake Brake System 42, 77 Brake Fluid FUEL MANAGEMENT...

  • Page 69: Suspension Mounting Bolts

    MAINTENANCE Periodic Maintenance Interval Table Item Frequency Page 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season CHASSIS Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fas- teners Suspension Shock Oil Cooling System Drive Shaft Bearing Jackshaft Bearings...
  • Page 70 The front suspension does not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with POLARIS Premium All Sea- son Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 62 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).
  • Page 71 MAINTENANCE Lubrication Driveshaft Bearing 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 72 (2). Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube. See page 98 for the part numbers of POLARIS products.
  • Page 73 MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4) and drain the oil into a drain pan. Allow the oil to drain completely. 3. Clean off all metal shavings from the plug.
  • Page 74 MAINTENANCE Spark Plugs It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.
  • Page 75 MAINTENANCE Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be white.
  • Page 76 1000 miles (1600 km). Tip: The direction of the arrows indicates the direction of flow through the fil- ter. Fuel Pump All fuel pump service must be performed by an authorized POLARIS dealer. Do not attempt to service the fuel pump.
  • Page 77 MAINTENANCE Fuel Filter/Fuel Lines See your POLARIS dealer for replacement of the under-tank fuel filter every 1000 miles (or annually). Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fuel compounds may occur.
  • Page 78 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. Carburetor Adjustments The frequency at which the carburetors are synchronized or balanced is important.
  • Page 79 MAINTENANCE Carburetor Water/Sediment Trap Most POLARIS snowmobiles contain patented carburetor bowl water/ sediment traps located at the bottom of each carburetor. The trap, con- sisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination.
  • Page 80 MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counter- clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.
  • Page 81 3. Brake Pad Material (Replace when thickness is less than 1/16I/1.5 mm). Excessive Lever Travel Hydraulic brakes are self- adjusting, but if excessive brake pad clearance develops, bring the machine to an autho- rized POLARIS dealer for inspection and adjustment.
  • Page 82 Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid. See page 98 for the part numbers of POLARIS products.
  • Page 83 MAINTENANCE 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.
  • Page 84 MAINTENANCE Lights Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb, clean it with an alcohol-moistened towel. Headlight Bulb Removal 1.
  • Page 85 MAINTENANCE Lights Taillight/Brakelight Replacement 1. Remove the screws securing the taillight lens. Remove the lens. 2. Push the bulb inward and turn it counterclockwise to remove it. 3. Install a new bulb. Push the bulb inward and turn it clockwise to secure it.
  • Page 86 POLARIS dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated. Do not lubri- cate clutch bushings.
  • Page 87 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 88 Drive Belt Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. POLARIS recommends the use of O.E.M. belts. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor performance.
  • Page 89 MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4I (3.2 cm).
  • Page 90 MAINTENANCE Track Maintenance Track Inspection WARNING! Broken track rods can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snow- mobile off the ground.
  • Page 91 MAINTENANCE Track Maintenance 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 92 MAINTENANCE Track Maintenance WARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment is critical for proper handling.
  • Page 93 MAINTENANCE Track Maintenance Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6.

  • Page 94: Track Alignment/Condition

    MAINTENANCE Track Maintenance n Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the machine with the track off the ground. 2.
  • Page 95 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary.
  • Page 96 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 97 MAINTENANCE Steering System n Ski Skags 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 con- trol while turning on hard-packed snow or ice.
  • Page 98 MAINTENANCE Steering System n Rail Slide Wear Measure slide thickness at several points along the rail. 7/16 Have your dealer replace the (1.1 cm) slide when it's worn down to the top of the wear limit indicator groove (H). Do not operate the snowmobile if slide thickness measures less than 7/16I (1.1 cm).
  • Page 99 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 98 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 100 MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with POLARIS Premium All-Season Grease or a similar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual.
  • Page 101 MAINTENANCE Extended Storage 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. Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely.

  • Page 102: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz./355 ml Aerosol) 2875035 Premium 2-Cycle Semi-Synthetic Oil (qt./.95 l) 2875036 Premium 2-Cycle Semi-Synthetic Oil (gal./3.8 l) 2875038 Premium 2-Cycle Semi-Synthetic Oil (2.5 gal./9.5 l) 2877882 VES Gold Plus 2-Cycle Oil (qt./.95 l) 2877883 VES Gold Plus 2-Cycle Oil (gal./3.8 l)

  • Page 103: Troubleshooting

    TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine oper- Drive clutch binding • Disassemble drive clutch to inspect ating RPM during shift weights for wear and free oper- acceleration or load ation.
  • Page 104 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive sys- Broken drive clutch • SEE YOUR DEALER. components Bearing failure/ • SEE YOUR DEALER. chaincase, jackshaft, or front drive shaft Drive belt surface • Inspect and replace as needed. flat spots Drive chain loose •...
  • Page 105 • Make sure fuel tank contains fuel. • Ice may be in fuel line, filter or pump. Add isopropyl alcohol to fuel system. On the standard POLARIS carburetor, the choke will not func- tion with the throttle depressed. See second item under Probable Cause"...
  • Page 106 TROUBLESHOOTING Rear Suspension Troubleshooting Problem Solution Rear suspension bot- • Adjust torsion spring preload to achieve proper static sag toms too easily (see page 32). • Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear track shock (see your dealer). •...
  • Page 107 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up.

  • Page 108: Warranty

    Your dealer receives frequent updates on changes, modifi- cations and tips on snowmobile maintenance, which may supersede informa- tion contained in this manual. Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you.
  • Page 109 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 110 WARRANTY Limited Warranty POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED 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. The war- ranty begins on the date of purchase.
  • Page 111 POLARIS' control. This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the snowmobile.
  • Page 112 How to Obtain Warranty Service If your snowmobile requires warranty service, you must take it to a POLARIS dealer authorized 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 113 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 vehi- cle Pre-Delivery Inspection, perform all applicable service bulletins and have the con- sumer sign the PDI form prior to delivery may void the warranty.
  • Page 114 WARRANTY Warranty Coverage and Exclusions Conditions and Exclusions Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair. The following items are excluded from warranty coverage in the event of a warranty claim: Spark Plugs Lubricants such as oil, grease, etc.
  • Page 115 How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your vehicle was purchased, War- ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle.
  • Page 116 You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and notices regarding your vehicle.
  • Page 117 This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 118 POLARIS dealer to perform any service that may be necessary for your vehi- cle. 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 119: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM) 150 mi.
  • Page 120 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 121 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 122: Index

    INDEX Accessories ....39 Cold Weather Drive-Away ..17 Adjustable Headlights ... 27 Controls and Linkage.
  • Page 123 Passenger Warning ....22 Polaris Products ....98 Preload, IFS Shock Spring ..29 Ice and Snow Build-up .
  • Page 124 INDEX Safety Decals ....21-24 Taillight/Brakelight Replacement . . . 81 Safety Symbols ....6 Throttle Cable .

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