Polaris 2011 FS IQ Widetrak Owner's Manual
  1. Manuals
  2. Brands
  3. Polaris Manuals
  4. Offroad Vehicle
  5. 2011 FS IQ Widetrak
  6. Owner's manual
Polaris 2011 FS IQ Widetrak Owner's Manual

Polaris 2011 FS IQ Widetrak Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading

Related Manuals for Polaris 2011 FS IQ Widetrak

Summary of Contents for Polaris 2011 FS IQ Widetrak

  • 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 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. 9922894 Rev 02 Printed in USA *9922894...
  • Page 5 • Victory Motorcycles ® • Low emission vehicles (LEVs) We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine we’ve ever pro-...
  • Page 6 POLARIS, THE WAY OUT and IQ are registered trademarks of POLARIS Industries Inc. 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..... 135 Troubleshooting ..... . . 136 Warranty .

  • Page 9: 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 10: Preservation Of The Environment

    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 11: 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 12: Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and 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 13 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 14 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 15: Riding Position

    SAFETY 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 16: Riding Apparel

    Riding Apparel 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 17: Rider Capacity

    SAFETY Operator Safety Rider Capacity Your snowmobile is designed for up to two riders. A decal on the console indicates that the vehicle is designed for one operator and one passenger only. WARNING! Operating improperly with a passenger could cause loss of control and result in serious injury or death.

  • Page 18: Cargo Capacity

    SAFETY Operator Safety Cargo Capacity See page 32 for cargo loading information. WARNING! Overloading the cargo carrier can cause loss of control resulting in severe injury or death. The maximum cargo carrier capacity is 75 lbs. (34 kg). Never exceed the cargo carrier capacity. Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills.

  • Page 19: 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 20: 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 21 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 22: 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 23: 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 24: Drive Belt

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

  • Page 25: Inadequate Snow Conditions

    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 26: Driving Responsibly

    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 27 SAFETY 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 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 28: Safety Decals And Locations

    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 Warning...

  • Page 29: Passenger Warning

    SAFETY Safety Decals and Locations Passenger Warning Snowmobiles designed for an operator and one passenger have a warn- ing decal on the console. For more information on operating with a pas- senger, see page 13. WARNING This vehicle is designed for operator and “ONE” passenger only. Track Warning WARNING Track...

  • Page 30: Reverse Warning

    Warning Reverse Warning Reverse Warning POLARIS snowmobiles equipped with standard 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 31: Operation Warning

    SAFETY 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 32: Features

    FEATURES 1. Nosepan 12. Taillights 2. Skis 13. Cargo Carrier 3. Front Bumper 14. Rear Bumper 4. Hood 15. Snow Flap 5. Headlight 16. Track 6. Windshield 17. Suspension 7. Mountain Bar 18. Grab Handle Heater Switch 8. Handlebar 19. Backrest Adjustment Knob 9.

  • Page 33: Features

    FEATURES 1. Glove Box 9. Handlebar Grip Warmer Switch 2. MFD Display 10. Thumbwarmer Switch 3. Ignition Switch 11. Throttle Control 4. Mirror 12. Engine Stop Switch 5. Shifter 13. MFD Control Switch 6. 12-Volt DC Outlet 14. Headlight Dimmer Switch 7.

  • Page 34: Features

    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- Raise/Lower ward for passenger use.

  • Page 35: Features

    The heater installed at the factory will be either a 110-volt heater with the appropriate plug (for use in North America) or a 220-volt heater with no plug (for international users). Note: See your POLARIS dealer for installation of the appropriate heater plug for your 220-volt heater. Glove Box...
  • Page 36 FEATURES Cargo Carrier WARNING! Overloading or towing improperly can alter vehicle handling and can cause loss of Cargo Carrier control. • Do not exceed the cargo carrier capacity. • Always reduce speed and allow greater distance for braking and turning when carrying cargo or a passenger, or when towing.

  • Page 37: Features

    FEATURES Passenger Grab Handle The position of the passenger grab handles can be adjusted for rider preference. Adjustment Bolt 1. Remove the adjustment bolt. 2. Reposition the grab handles to one of the two adjustment positions on the grab handle tube between the operator seat and the passenger seat.

  • Page 38: Features

    2. If the light illuminates again, determine whether engine RPM or vehicle speed is limited, then check the charts on page 35 to identify the cause. Tip: If you are unable to determine the cause of an illuminated MIL, please see your POLARIS dealer.

  • Page 39: 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 Function...

  • Page 40: 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 41: Features

    FEATURES Instrumentation MFD Component Identification Item 1 Analog Gauge (if equipped) 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 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage...

  • Page 42: 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- 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 43: Features

    FEATURES Instrumentation MFD Settings Speedometer/Tachometer If your model is equipped with both analog and digital displays, the speedometer and tachometer can be viewed in either display. If the ana- log display is set to show speedometer readings, the digital screen will automatically display the tachometer (option 1).

  • Page 44: Features

    FEATURES 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 45: 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 46 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 47: Features

    FEATURES 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 48 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 49: Features

    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 50: 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 51: Features

    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 52: 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 53: Features

    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 54: The Perfect Fit

    • Camber (see your dealer) Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your POLARIS dealer for assistance before attempting 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 55: Rear Suspension Adjustments

    • 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 56 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the dis- tance 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 57: Torsion Spring Preload

    THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. This adjustment is easier to make if tension is relieved from the spring. Exercise extreme caution if you use this method of adjustment, and follow the steps below carefully.
  • Page 58 THE PERFECT FIT Rear Suspension Adjustments Limiter Strap Position (Ski Pressure) The following information is provided only as a guideline to High be used for initial suspension set-up. Your set-up may vary based on your desired riding style. High: Limiter strap in high position increases ski pressure Low: Limiter strap in low position decreases ski pressure...

  • Page 59: Shock Compression Valving

    THE PERFECT FIT Rear Suspension Adjustments Shock Compression Valving The rear track shocks for this model are gas charged shocks. The valv- ing on the gas charged shocks is pre-set.

  • Page 60: Handlebar Adjustments

    THE PERFECT FIT Handlebar Adjustments Use the following steps to adjust handlebar angle at the handlebar block. 1. Remove the mountain bar. 2. Remove the handlebar cover. Mountain 3. Using a 7/16" wrench, loosen the four nuts on the bottom of the adjuster block.
  • Page 61 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 snowmo- bile. Use of unapproved parts and accessories may result in: •...

  • Page 62: 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. Item See Page Drive Belt Condition...

  • Page 63: Before Starting The Engine

    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 64: Hood Latches

    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 65: 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 66: Parking Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Brake Parking Brake Use the parking brake lever lock Lever Lever Lock only when you want the snowmo- bile to remain stationary; for exam- ple, when parked on an incline for a period of five minutes or less.
  • Page 67 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 68: Suspension Inspection

    PRE-RIDE INSPECTIONS 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.

  • Page 69: Start The Engine And Check

    PRE-RIDE INSPECTIONS 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 70 OFF position, then restart. WARNING! Operating a snowmobile with accident damage can result in serious injury or death. Do not operate the snowmobile if components have been damaged in a collision or tip-over. Have the snowmobile inspected by an authorized POLARIS dealer.

  • Page 71: Operation

    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 72 POLARIS recommends the use of Performance Synthetic 4-Stroke oil (PS-4 or PS-4 Plus) for this engine. See page 85. NOTICE: Use of non-recommended oil may cause serious engine damage.

  • Page 73: Starting The Engine

    OPERATION 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 74: 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 75 OPERATION 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 76 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 77: Stopping The Snowmobile

    OPERATION Stopping the Snowmobile The following chart lists methods for stopping the snowmobile. See page 76 for more information about the engine stop switch. THROTTLE SYSTEM WHAT IT DOES CONDITION Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch Interrupts ignition circuit...

  • Page 78: Fuel Level

    Never use deicers or additives containing methanol. POLARIS also recommends the use of Carbon Clean Plus. See page 135 for the part numbers of POLARIS products. If you use oxygenated fuel containing ethanol, additional alcohol deic-...
  • Page 79 OPERATION 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 80 The switch operation is checked through the engine con- trol unit for correct operation. 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 illuminated.
  • Page 81 The lever and cable must return to the idle position quickly and completely. 4. If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures. 5. If the engine doesn't start, take the snowmobile to an authorized POLARIS dealer for service.

  • Page 82: Reverse Operation

    OPERATION Reverse Operation WARNING! Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the gearcase or transmission if shifting is attempted when the engine is operating above idle speed.

  • Page 83: 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 84: 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 85 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 86 MAINTENANCE Periodic Maintenance Interval Table O = Perform Service INITIALLY X = Replace Miles (km) Item Instructions 1500 (240) (800) (2400) (see referenced pages) Engine Stop Switch Test for proper operation. Do not operate if switches Ignition Switch fail, see your dealer for ser- Throttle Safety Switch vice.
  • Page 87 MAINTENANCE Periodic Maintenance Interval Table O = Perform Service INITIALLY X = Replace Miles (km) Item Instructions 1500 (240) (800) (2400) (see referenced pages) Coolant Hoses Inspect, replace if worn or damaged Heat Exchangers Inspect, replace if damaged Fuel Lines 101 Inspect, replace if worn or damaged Battery...
  • Page 88 MAINTENANCE Periodic Maintenance Interval Table O = Perform Service INITIALLY X = Replace Miles (km) Item Instructions 1500 (240) (800) (2400) (see referenced pages) Engine Mounts Inspect, replace if worn or damaged Spark Plugs Inspect condition/gap, replace as needed Exhaust System 103 Check muffler and pipe con- dition, replace damaged or missing components, clean...
  • Page 89 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 90 MAINTENANCE Engine Oil n Oil Level Check Note: Read the entire oil check procedure before checking the oil level. The oil level will rise as engine temperature increases. The oil level will be lower when the engine is cold. To obtain a proper oil level reading, the snowmobile must be on a level surface, and the engine coolant tem- perature must be between 145 and 160°...
  • Page 91 MAINTENANCE 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 92 MAINTENANCE Engine Oil n Oil Level Check Fill mark for oil changes (at specified coolant temperature) 8. Maintain the oil level in the safe operating range, between the upper and lower marks on the dip- Safe operating range stick. If the level is low, add the recommended oil in small increments, about 2 ounces (60 ml), and recheck the level.

  • Page 93: 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.

  • Page 94: Oil Change

    Table beginning on page 82. Clean the foam oil breather element with each engine oil change. See page 94. Always use the recommended oil. See page 86, or see your POLARIS dealer about oil change kits, which contain a new filter and the recom- mended oil.
  • Page 95 MAINTENANCE 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 96 MAINTENANCE 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 97 MAINTENANCE 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. OIL TO ADD AT STEP 26 MODEL Ounces...
  • Page 98 MAINTENANCE 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 99: Driveshaft Bearing

    MAINTENANCE Lubrication Driveshaft Bearing Using a needle-nose grease Grease Hole gun, inject grease into the grease hole on the top edge of the bearing flangette until grease purges from the seal on the inside of the tun- nel. This should take approximately two pumps each.

  • Page 100: Rear Suspension

    MAINTENANCE 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 82 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

  • Page 101: Gearcase Oil

    Maintenance Table beginning on page 82. POLARIS recommends the use of POLARIS PS-4 PLUS engine oil for this gearcase. See page 135 for the part numbers of POLARIS products. NOTICE: Mixing brands or using non-recommended lubricants could result in excessive wear to chain, sprockets and bearings.

  • Page 102: Gearcase Oil Change

    Gearcase Oil Change The drain plug is located on the bottom of the gearcase. Tip: 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 103: Spark Plugs

    MAINTENANCE 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 104 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 105: Intake Filters

    Do not attempt to service the fuel pump. Fuel Filter See your POLARIS dealer for replacement of the fuel filter at the inter- vals outlined in the Periodic Maintenance Table beginning on page 82. Contaminated or poor quality fuel will shorten the life of the fuel filter and result in poor engine performance.

  • Page 106: Alternator Belt Inspection

    MAINTENANCE 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 107: 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 135 for the part numbers of POLARIS products. 6. Close the hood.

  • Page 108: 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 135 for the part numbers of POLARIS products. 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 109: Coolant Level

    MAINTENANCE Cooling System n Coolant Level The engine coolant level is controlled by the recovery system. The recovery system components are: • Coolant recovery bottle • Coolant reservoir • Pressure cap “COLD FILL” Level • Connecting hoses Always maintain the coolant level at the “COLD FILL”...
  • Page 110 MAINTENANCE 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 111: Flushing The Cooling System

    Have your POLARIS dealer perform this service. Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main- tenance Table beginning on page 82.
  • Page 112 MAINTENANCE Cooling System Bleeding the Cooling System 5. Remove the bleed screw on the radiator. Do not lose the washer. 6. Remove the coolant pressure cap from the coolant reservoir. 7. Fill the coolant reservoir until coolant bleeds out the radiator bleed screw removed in step 4.
  • Page 113 MAINTENANCE Cooling System Bleeding the Cooling System 14. Monitor engine coolant temperature. When it reaches 195° F. (90 ° C.), remove the vice-grip pliers. 15. Continue monitoring temperature until it reaches 205° F. (96 ° C.). Fill the reservoir completely full, then install and tighten the pres- sure cap securely.

  • Page 114: Hydraulic Brake Inspection

    MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 61. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate, approximately 1/16" (1.5 mm). A kit is avail- able for replacing brake pads.
  • Page 115 1. Position the handlebars so the master cylinder is level. 2. Remove the master cylinder cover. 3. Add DOT 4 brake fluid only. Do not overfill. See page 135 for the part numbers of POLARIS products.

  • Page 116: Bleeding The Hydraulic Brake System

    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 117 MAINTENANCE Brakes Bleeding the Hydraulic Brake System 5. Close the bleeder valve and release the brake lever. 6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles. WARNING! Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock, resulting in serious injury or death.

  • Page 118: Removing Halogen Bulbs

    MAINTENANCE 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 119: Installing Halogen Bulbs

    MAINTENANCE Lights Installing Halogen Bulbs 1. Hold the bulb by its metal base and install it into the wire harness. 2. Insert the bulb into the housing. 3. Connect the spring to the housing. 4. Carefully flip the spring back into the housing, placing it around the wire harness.

  • Page 120: Electrical System

    MAINTENANCE Electrical System RELAY LABEL FUSE LABEL ITEM POWERED START SOLENOID Ground side of start solenoid RELAY SPARE 20A None ACCESSORY Accessory plugs EMERGENCY SPARE 30A CHASSIS High beams RELAY Low beams Handwarmers CHASSIS Thumbwarmer Passenger handwarmers Work light Tail lamp Brake lamp Alternator coils Exhaust sensor...

  • Page 121: 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 122: 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 123: Drive Belt Adjustment

    MAINTENANCE Clutch System Drive Belt Adjustment Belt deflection should be adjusted without removing the clutch from the jackshaft. 1. Loosen the 7/16" jam nut on the belt width adjuster. 2. Using a 1/8" Allen wrench, adjust the threaded set screw as needed. Tip: Turn the set screw in (clockwise) to increase the distance between the sheaves and out (counterclockwise) to decrease the distance.

  • Page 124: 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 oper- ating in a forward motion.

  • Page 125: Drive Belt Installation

    MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer circum- ference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the break-in period.

  • Page 126: 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 machines 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 127: Track Lubrication

    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 128: 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 129 MAINTENANCE Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic rail slide. Idler Shaft Adjusting Bolt Lock Screw If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7.

  • Page 130: 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 Minimum wear limit indicator groove to Thickness indicate the minimum permissi- ble slide thickness.

  • Page 131: 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 132: 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 133: Ski Skags

    MAINTENANCE 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 134: 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 135: 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 136 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 137: 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 135 for the part numbers of POLARIS products. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts.

  • Page 138: Engine Protection

    MAINTENANCE 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 139: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricants 2876244 Performance Synthetic 2W-50 4-Cycle Oil (PS-4 PLUS) (qt.) 2876245 Performance Synthetic 2W-50 4-Cycle Oil (PS-4 PLUS) (gal.) Gearcase Lubricants (use PS-4 PLUS Engine Oil for this gearcase) Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season (3 oz.)

  • Page 140: Troubleshooting

    TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Speed, RPM or Boost is Limited Probable Cause Solution Engine Management System RPM See causes on page 35. Reduction Mode is activated Jammed clutch Check for twisted belt or broken spring. See your dealer. Jammed track Remove any foreign objects.
  • Page 141 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Turns Over, Fails to Start Probable Cause Solution Out of fuel Refuel. Water is present in fuel See your dealer. Old or non-recommended fuel Replace with fresh recommended fuel. Fouled or defective spark plugs Inspect plugs and replace if necessary.
  • Page 142 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Runs Irregularly, Stops or Loses Power Probable Cause Solution Engine Management System RPM See causes on page 35. Reduction Mode is activated Low battery voltage Recharge the battery to 12.8 VDC. Water is present in fuel See your dealer.

  • Page 143: Engine Overheating

    TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Overheating Probable Cause Solution Inadequate snow conditions Stop and cool the engine. Drive into snow frequently to prevent overheating. See page 21. Low coolant Stop and cool the engine. Check the cool- ant level. See page 105. Check for leaks. Bleed the system if the coolant level is extremely low.

  • Page 144: Suspension Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension • Set static sag (see page 52). Adjust torsion spring blocks or bottoms too easily install optional torsion springs to achieve correct sag dimensions. Rides too stiff in rear • Check for binding suspension components and grease all pivot points.
  • Page 145 TROUBLESHOOTING Drive Belt Wear/Burn Cause Solution 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 machine in extremely cold weather and warm it up. Break machine loose from the snow.

  • Page 146: Warranty

    WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty infor- mation contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile mainte- nance, which may supersede information contained in this manual.
  • Page 147 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 148: Limited Warranty

    POLARIS’ control. This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the snowmobile.
  • Page 149 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 150 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 151 WARRANTY 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 152 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 153 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 154 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 155: 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 156 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 157 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 158: Index

    INDEX Accessories ....57 DC Outlet, 12-Volt ....33 Alternator Belt Inspection .
  • Page 159 Instrumentation ....37-49 POLARIS Products... . . 135 Intake Filters ....101 Pre-Ride Checklist .
  • Page 160 INDEX Snow Conditions ....21 Throttle Cable Lubrication ..95 Spark Plugs ....99-100 Throttle Lever .

Table of Contents