Page 1 2004 2004 Touring & WideTrak Touring & WideTrak Snowmobiles Snowmobiles Owner's Manual Owner's Manual for Vehicle Maintenance for Vehicle Maintenance and Safety and Safety...
Page 2 Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust, which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm, onto the snow on...
Page 3 What’s the hottest thing on snow? A Polaris owner’s Web site, designed just for YOU! Check it out... www.polarisindustries.com/owner Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out...
Page 4 Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
Page 5 S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...
Page 6: Table Of Contents
Maintenance This section defines your role, and your dealer’s role, in your snowmobile’s regular maintenance. Polaris Products Troubleshooting This section is a quick reference guide to solving problems. Warranty ....... .
Page 7: Introduction
Important Notes for Owners and Drivers n After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. n The illustrations and photos used in this manual are general representations. Your model may differ. n Follow the maintenance program outlined in this manual.
Page 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. If both keys are lost, the ignition switch must be replaced.
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 symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
Page 11: Operator Safety
We strongly recommend that the operator 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 Away From Moving Parts Be alert when riding, and remain properly seated to stay clear of the track. Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Serious injuries may result if hands, feet, or clothing become entangled in the track.
Page 13: Riding Position
Operator Safety Riding Position Improper riding position may seriously reduce your ability to control the machine and may result in serious injury or death. Always be properly seated and in position to control your vehicle. Operating a snowmobile requires skill and balance for proper control. Rider positions may vary from person to person as each becomes more skilled;...
Page 14: Cargo Overload
SAFETY Operator Safety Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier. Control becomes more difficult with two people on board.
Page 15: Excessive Speed
A decal on the console of these models indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only. See page 23 for decal location.
Page 16: 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 17: Ice And Snow Build-Up
Operator Safety Ice and Snow Build-up 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 18: Driving In Hilly Terrain
SAFETY 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 19: Driving Downhill
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: Intake Silencer
Maneuverability will change for lighter operators or machines designed to carry a load or a passenger. Maintenance Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 73 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.
Page 21: Powder Snow Operation
Operator Safety Powder Snow Operation Moveable hood closures are included on some Polaris snowmobiles. They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20_F), Polaris recommends closing the upper hood closure.
Page 22: Driving Responsibly
SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
Page 23 Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART (°F) Estimated Wind Speed in MPH Speed in MPH Calm Wind Speeds Great- Little Danger er Than 40 MPH (For Properly Have Little Added Have Little Added...
Page 24: Safety Decals And Locations
If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
Page 25: Track Warning
The decal specifies the maximum recommended weight capacity for the carrier. Never exceed the maximum recommended weight capacity for your machine. Passenger Warning Polaris touring models and the WideTrak are designed for the operator and one passenger. For more information on operating with a passenger, see page 13.
Page 26 SAFETY Safety Decals and Locations Standard Reverse Warning The Polaris WideTrak snowmobile is equipped with standard reverse. The reverse warning decal is located above the instrument housing.
Page 27 SAFETY Safety Decals and Locations Electronic Reverse Warning Polaris snowmobiles equipped with electronic reverse will have the electronic reverse warning decal. WARNING AVERTISSEMENT...
Page 28: Operation Warning
SAFETY Safety Decals and Locations Operation Warning Operation warning decals are present on WARNING the console of all Polaris snowmobiles, in both French and English. Touring Models WARNING WideTrak...
Page 29 SAFETY Safety Decals and Locations Operation Warning AVERTISSEMENT Touring Models AVERTISSEMENT WideTrak...
Page 30: Features
FEATURES Some Polaris snowmobiles are equipped with special features. Operating controls and special feature controls are illustrated on this page. Not all models come with all special features. Refer to your Owner’s Manual Supplement for the features on your machine.
Page 31 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Backrest 7. Storage Compartment 8. Taillights 9. Rear Bumper 10. Snow Flap 11. Passenger Hand Hold 12. Track 13. Suspension 14. Trailing Arm 15. Nosepan 16. Front Bumper 17. Skis 18.
Page 32: 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 33: Shock Absorber Components
Front Suspension Adjustments Always verify ski alignment before making adjustments to the IFS. See page 114 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. For the best ride, the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming.
Page 34: Shock Damping
THE PERFECT FIT Front Suspension Adjustments Shock Damping Adjustments to the compression stiffness of Indy Select or RydeFX SOLO shocks can be made by turning the adjustment screw (Select) or actuator (SOLO), located near the base of the shock (A). This adjustment is the easiest to perform and it should be considered first.
Page 35: Front Suspension Adjustments
Front Suspension Adjustments Adjusting Front Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. To increase front shock spring preload, grasp the spring and turn it to the right.
Page 36: Shock Valving
Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a Polaris dealer. Front Springs For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn’t sufficient and...
Page 37: Suspension Performance Tips
Bogie wheel kits are available from your dealer. S Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.
Page 38 THE PERFECT FIT Edge 136 Rear Suspension Adjustments (Indy 340 Touring and Sport Touring) Initial Spring Preload Setting (Sag Method) To set up the EDGE rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension.
Page 39: Rear Spring Tension
THE PERFECT FIT Edge 136 Rear Suspension Adjustments (Indy 340 Touring and Sport Touring) Rear Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information.
Page 40: Suspension Coupling
Contact your dealer for more information. Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other.
Page 41 THE PERFECT FIT Edge 136 Rear Suspension Adjustments (Indy 340 Touring and Sport Touring) Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm.
Page 42: Weight Transfer During Acceleration
THE PERFECT FIT Edge 136 Rear Suspension Adjustments (Indy 340 Touring and Sport Touring) Weight Transfer During Acceleration Rear Rear Scissor Stop (RRSS) The preferred method for controlling weight transfer during acceleration of the EDGE rear suspension is by adjusting the RRSS. The RRSS is located in the best overall trail riding position when delivered from the factory.
Page 43 Edge Touring Suspension (ETS) Adjustments Torsion Springs Two torsion springs are used on the rear arm of the ETS. Preload adjustments can be made by turning the rectangular adjusters with a spark plug wrench. The firm torsion spring should be used if frequent bottoming is encountered during two up riding on rough trails.
Page 44 THE PERFECT FIT Edge Touring Suspension (ETS) Adjustments Initial Setup and Calibration The following information has been compiled to assist you in tuning your ETS to its maximum potential. The Ride Control Adjuster (RCA) 1. Refer to the initial setup reference chart (located under the hood of your snowmobile and on page 41) to determine the desired RCA position.
Page 45 ETS ACE Adjustments The ETS ACE (Adjustable Control Electronics) is a new feature available for some ETS rear suspensions. It enables a rider to easily adjust the suspension for weight and riding style. The ETS ACE is an electronically controlled module that replaces the standard ETS RCA.
Page 46 THE PERFECT FIT ETS ACE Adjustments ETS ACE Settings IMPORTANT NOTES: The time to move one position can take up to 12 seconds depending on the rear shock loads. Due to alternator limitations, the ACE module will operate only at engine speeds above 3500 RPM.
Page 47 WideTrak Rear Suspension Adjustments Rear Spring Settings Rear spring adjustment is primarily a control for riding comfort. To check for the recommended settings: 1. Lift the rear of the machine to relieve the rear springs. 2. Slowly lower the machine and measure the distance between the ground and the running board.
Page 48 THE PERFECT FIT Handlebar Adjustments Standard Handlebars Follow these steps to adjust the handlebars for a personal fit. 1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts (A). 2. Using a 7/16″ (11 mm) wrench, loosen the four nuts on the bottom of the adjuster block (turn handlebar to left or right for access to back...
Page 49 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories.
Page 50: Traction Products
Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. NOTE: Polaris does not recommend the use of traction products on WideTrak snowmobiles. NOTE: Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products.
Page 51 Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products. Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage.
Page 52: Wear Strips
THE PERFECT FIT Accessories Wear Strips To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Several wear strips are available. See your dealer for more information. Some models are manufactured with tunnel wear strips or wear strip coolers installed.
Page 53: Pre-Ride Inspections
Before Starting the Engine Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and refer to it often. We’ve attempted to provide as much information as possible to alert you to the safety requirements of snowmobiling.
Page 54: Hydraulic Brakes
Also check for the presence of air in the fluid system. Refer to page 99 for more information, or see your dealer for service. Replace brake fluid at least every two years with Polaris DOT 3 high temperature brake fluid. All DOT 3 brake fluid is not alike. Use only Polaris brake fluid.
Page 55: Before Starting The Engine
Before Starting the Engine Mechanical Brakes Brake Lever Travel Firmly depress the brake lever. Measure the distance (A) between the lever and brake block. The distance should be no more than 3/4″ (1.9 cm). If the distance is greater than this recommendation, the brake cable must be adjusted.
Page 56: Track Inspection
PRE-RIDE INSPECTIONS Before Starting the Engine Check for Proper Operation of Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated.
Page 57: Start The Engine And Check
Start the Engine and Check n Transmission: Make sure the reverse is not engaged before starting your machine. n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and start the engine.
Page 58: Operation
OPERATION Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces.
Page 59: Starting A Warm Engine
Starting the Engine Starting a Cold Engine (Electric Start) Do not depress the throttle until the engine starts. 1. Flip choke toggle to FULL ON. 2. Pull kill switch (shut-off switch) up to RUN. 3. Turn key to START and crank engine. 4.
Page 60: Engine Break-In
No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.
Page 61: Oil Injection System
RPM and throttle valve opening. Variable Exhaust System We recommend the use of Polaris VES 2-cycle oil in all snowmobile engines equipped with variable exhaust valves (see chart below). Oil Recommendations The only source of engine lubrication for your engine comes from lubrication added to the fuel and oil injection systems.
Page 62: Track Warm-Up
OPERATION 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 63 Fuel Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Page 64: Premium Fuel Switch
OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used. Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane gasoline available across the country, so we encourage the use of premium fuel when possible.
Page 65: 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 66: Low Oil Level
Always do a visual check of the oil level when refueling. When the oil reaches the low level mark, add one U.S. quart of recommended oil. The Polaris oil cap on the oil tank may be vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.
Page 67: Jetting Guidelines
In higher elevations and higher temperatures, the air is less dense. Carburetors on most Polaris models are calibrated for an altitude of 0-2000 ft. (0-600 meters) and ambient temperatures between -10 to +10 F.
Page 68: Engine Stop Switch
OPERATION Engine Stop Switch Push down on the engine stop switch (A) to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position.
Page 69: Throttle Lever
When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the machine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealer for service as soon as possible. WARNING...
Page 70: Emergency Stopping
OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 66 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch Tether Switch (Option) Excessive or repetitive use of brakes for high speed stops will...
Page 71: Emergency Starting
Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Machine’s equipped with electric start have a recoil for emergency starting. On non-electric start models, if the recoil starter system fails, an emergency start strap is provided in the kit. Serious injury can result from wrapping the start strap around your hand while using the emergency starting procedure.
Page 72: Reverse Operation
OPERATION Reverse Operation Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Always look behind the vehicle before and while backing. Always avoid sharp turns. Shift to or from reverse only when stopped. Always apply throttle slowly.
Page 73 Reverse Operation Electronic Reverse (PERCt) Electronic reverse will activate only if the engine is below 4000 RPM (3000 RPM on fan cooled models). If your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described below (Altitude Settings).
Page 74: Daily Storage
The track should be suspended approximately 4″ (20 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 information. Towing For your safety, do not attempt to using the tow hitch until you’ve read...
Page 75: Maintenance
Personal safety is critical when attempting to service or adjust your snowmobile. If you’re not familiar with safe service or adjustment procedures and the use of tools, or if you don’t feel comfortable performing these tasks yourself, contact an authorized Polaris dealer for service.
Page 76: Maintenance Chart
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 Check brake operation and...
Page 77 Grease center steering arm(s) Lubricate steering post support bracket and pivot (aerosol) Check cylinder base stud torque on all Polaris engines. (Specifica- tion: 32 ft. lbs ± 2 ft. lbs.) (Dealer) Grease lower steering post pivot Flush Chaincase Grease driveshaft bearing...
Page 78: Maintenance Log
This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. 150 Mile (240 km) Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date 500 Mile (800 km) Maintenance Inspection...
Page 79 Maintenance Log Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service MAINTENANCE Mileage Mileage...
Page 80 S Grease the steering post lower pivot. S Grease the rear suspension pivot shafts (raise the rear of unit). A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmobiles. See page 126. Aerosol...
Page 81 MAINTENANCE Lubrication The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the suspension.
Page 82: Jackshaft Bearing Greasing
MAINTENANCE Lubrication Jackshaft Bearing Greasing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps).
Page 83: Throttle Cable
MAINTENANCE Lubrication Throttle Cable Lubricate the throttle cable (1) lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown. Choke and Cable Lubricate the choke slide (2) and cables lightly with oil or grease. Before turning the engine off, operate the choke intermittently to draw moisture out of the choke plunger area and reduce the...
Page 84 The oil level should be between the “safe” marks on the dipstick (A). See your Polaris dealer for the recommended oil for your machine. Do not overfill. NOTE: Clean the magnetic plug (B) every 500 miles (800 km) and whenev- er checking or changing lubricant.
Page 85: Chaincase Oil Level
“safe” marks on the dipstick (A). Add Polaris chaincase oil (PN 2871280) through the dipstick opening. Do not overfill. See page 126 for the part numbers of Polaris products. Flush the chaincase after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.
Page 86: General Maintenance
Owner’s Manual Supplement for specific information. S Spark plug torque is 18-22 ft. lbs. (24.4-30 Nm). S Always carry spare spark plugs in case of an emergency. Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. CAUTION CAUTION...
Page 87 General Maintenance Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. A hot exhaust system and engine can cause serious burns.
Page 88: Intake Filter
MAINTENANCE General Maintenance Intake Filter The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. Operating the snowmobile with the intake filters removed may cause carburetor icing.
Page 89: Water Pump Belt Inspection
Maintenance of the VES is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles (800-1600 km), bring the machine to an authorized Polaris dealer to have the VES disassembled, inspected, and cleaned. NOTE: To ensure maximum performance and minimize required maintenance, follow the oil recommendation chart on page 59.
Page 90: Water/Sediment Trap Service
MAINTENANCE General Maintenance Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination.
Page 91: Oil Filter
The oil filter should be changed annually or every 1200 miles (1920 km). Inspect oil line condition at 1000 miles (1600 km). Polaris oil filters are specially designed for use on Polaris products. We strongly recommend the use of only Polaris replacement parts.
Page 92: Carburetor Adjustments
It’s your dealer’s responsibility to make sure the correct main jet is installed. 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 93: Exhaust System
General Maintenance Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.
Page 94: Coolant Level
MAINTENANCE General Maintenance Coolant Mixture The coolant supplied in the system is a 50/50 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing at temperatures to -34° F (-37° C). If greater protection is required, the percentage of antifreeze to water may be increased.
Page 95: Flushing The Cooling System
50/50 or 60/40 mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile. Bleeding the Cooling System If the pressure cap needs replacement, contact your dealer for the correct part.
Page 96: Bleeding The Cooling System
MAINTENANCE General Maintenance Bleeding the Cooling System If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced. Surge Tank Models 1.
Page 97: Drive Chain Tension
General Maintenance Drive Chain Tension To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. Loosen the adjuster bolt jam nut (A).
Page 98: Hydraulic Brake Inspection
MAINTENANCE General Maintenance Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Firmly depress the brake lever and measure the clearance between the lever and handlebar grip. This distance, called brake lever reserve (A), should be no less than 1/2″ (1.3 cm). Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16″).
Page 99: Brake Components
5. Brake Pad Material (Replace when thickness is less than 1/16″). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as described on page 96, the machine should be returned to an authorized Polaris dealer for inspection and adjustment.
Page 100: Brake Fluid
Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately. Use only Polaris DOT 3 high temperature brake fluid. See page 126 for the part numbers of Polaris products. On some models, the brake fluid level can be seen through a plastic sight glass in the brake reservoir.
Page 101: Bleeding The Hydraulic Brake System
General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. 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 102 MAINTENANCE General Maintenance Mechanical Brake Lever Travel Improper brake adjustment could result in brake failure and lead to serious injury or death. See your dealer for brake service. Frequently inspect the brake lever reserve (A), which is the clearance between the lever and the brake block.
Page 103: Headlight Adjustment
General Maintenance Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure: 1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall.
Page 104 MAINTENANCE General Maintenance Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer. NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
Page 105: Taillight Replacement
General Maintenance Taillight Replacement 1. Remove the rear storage cover (A) if equipped. 2. Depending on your model, remove the screws (B) securing either the taillight housing (C) or the lens cover (D). 3. Remove and replace the bulb (E). 4.
Page 106: Clutch System
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 lubricate clutch bushings.
Page 107: Drive Belt Removal
General Maintenance Periodically check the condition and tension of the drive belt, and always carry a spare belt. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. The following procedures apply to standard, electronic reverse and TEAM driven clutches.
Page 108: Drive Belt Installation
MAINTENANCE General Maintenance Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack (A). NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them.
Page 109: Drive Belt Adjustment
B. This measurement should be 1 1/4”. Drive Belt Adjustment Polaris Standard Reverse Clutch Belt deflection can be adjusted without removing the clutch from the jackshaft. 1. Pull the belt into the driven clutch to slightly open the sheaves.
Page 110: Torque Stop
MAINTENANCE General Maintenance Torque Stop If your snowmobile is equipped with an engine torque stop (1), periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be a minimum of .010″ to a maximum of .030″ from the engine case (2).
Page 111: Tool Kit
Indy Select or AFX shocks) 8. Box End Wrench Always keep the tool kit with the snowmobile. If necessary, a replacement tool kit may be purchased from your Polaris dealer. Chain Tension Maintain the proper chain tension as outlined on page 95.
Page 112: Fall Tune-Up
Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Maintenance Items The tools and maintenance items mentioned in this book, as well as a long line of other Polaris accessories, are available at your Polaris dealer.
Page 113: Track Tension
Track Maintenance 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 114: Track Tension Data
MAINTENANCE Track Maintenance Track Tension Data Suspension Edge 136 Edge Touring ETS ACE WideTrak 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.
Page 115: Track Lubrication
Track Maintenance 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. Using a hoist, safely lift and support the rear of the snowmobile off the ground.
Page 116: Steering System
Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.
Page 117 MAINTENANCE Steering System 10″ 10″ Edge IFS 10″ 10″ WideTrak...
Page 118: Steering Inspection And Adjustment
MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check fasteners and tighten if necessary. Specific fasteners that should be checked are marked with a in the following illustrations. All Steering Except CRC Edge IFS Steering System...
Page 119: Ski Skags
Steering System 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 120: Suspension Maintenance
MAINTENANCE Suspension Maintenance Hi-Fax Wear Check Hi-fax wear by measuring the thickness at several points along the rail (A). Replace Hi-fax when a thickness of 7/16″ is reached (3/8″ on WideTrak models). See your dealer for Hi-fax replacement. If excessive Hi-fax wear occurs due to poor snow conditions, additional wheel kits are available from your dealer.
Page 121: Cleaning And Preservation
MAINTENANCE Suspension Maintenance Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip: n Check rear idler wheel bolts for tightness.
Page 122: Clutch And Drive System
See page 126. Always add Premium Carbon Clean or a fuel conditioner/stabilizer to the fuel tank. See page 126 for the part numbers of Polaris products. Follow the instructions on the can, running the engine for five minutes to get additives through the entire fuel system.
Page 123: 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 126 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 124: Transporting The Snowmobile
MAINTENANCE Extended Storage Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely. See illustration. Transporting the Snowmobile Whenever the snowmobile is transported: 1.
Page 125: 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 immediate medical attention. KEEP OUT OF REACH OF CHILDREN. EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Call physician immediately.
Page 126: Battery Removal
MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When cleaning is necessary, remove the corrosion with a stiff wire brush. Wash terminals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry with clean shop towels.
Page 127: Battery Installation
Battery When your snowmobile is placed in storage for one month or more: S Remove the battery. S Charge it to the proper level. S Store it in a cool dry place. S Check and/or charge monthly. Before using the battery, take it to your dealer for testing and recharging.
Page 128: Polaris Products
POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Oil (gal.) 2874438 VES II Synthetic 2-Cycle Oil (qt.)
Page 129: Troubleshooting
Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Erratic engine Drive clutch binding operating RPM during accelera- tion or load tion or load variations Driven clutch malfunction Harsh drive Drive belt worn or...
Page 130 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Noise in drive Broken drive clutch components system Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose or worn, sprocket teeth broken Poor low RPM Worn drive belt performance Excessive belt/sheave clearance...
Page 131 Make sure the fuel valve is “ON”. Check tank level and fill up with correct fuel. Ice in fuel line, filter, or pump. On the standard Polaris carburetor, the choke will not function with the throttle depressed. See second item under “Probable Cause” of “Engine continually backfires”.
Page 132: Suspension Troubleshooting
TROUBLESHOOTING Suspension Troubleshooting Edge 136 Suspension Problem Solution (perform only one change at a time) Rear suspension - Increase torsion spring preload. bottoms too easily - Increase rear track compression damping by turning screw on rear track shock clockwise (factory position full soft). - Increase torsion spring wire diameter.
Page 133 Suspension Troubleshooting Edge Touring Suspension (ETS) and ETS ACE Problem Solution (perform only one change at a time) Rear suspension - Adjust RCA forward (see setup decal under hood). bottoms too easily - Adjust coil over spring on front track shock to increase preload - 1”...
Page 134: Belt Troubleshooting
TROUBLESHOOTING Belt Troubleshooting Causes Driving at low RPM Insufficient warm-up Towing at low RPM Riding with high RPM and slow speed (8000 RPM/10 MPH) Ice and snow build-up between track and tunnel Poor engine performance Loading machines onto trailers Clutch malfunction Slow, easy clutch en- gagement Belt Wear/Burn Diagnosis...
Page 135: Warranty
2. Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. 3. Polaris warranty will aid in notifying the proper owner when a unit is recovered. 5. Details of trouble experienced 6.
Page 136: 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 137: 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 138 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 139 S Failures caused due to improper adjustments. Failure due to unauthorized service. S Failures due to lack of service as required in the owner’s manual or Polaris updates. This includes off-season storage as listed in the owner’s manual. S Failure due to use of unauthorized parts or modifications.
Page 140 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 141: Index
Accessories ....Air Box ......Air Pollution .
Page 142 Passenger PERC ......Plug Cleaning POLARIS PRODUCTS Powder Snow Operation PRE-RIDE INSPECTIONS . . .
Page 143 Spark Plugs ....Spring Preload, Edge 136 ... Spring Tension, Rear, Edge 136 Start the Engine and Check Starting .
Page 144 For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone (763) 417-8650 Fax (763) 542-0599 Part No. 9918226 Rev 02 Printed in USA...

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