Page 3 Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Page 4 • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. M-10 is a trademark of Fast Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication.
Page 6: Table Of Contents
Polaris Products..... . . 149 Troubleshooting ..... . . 150 Warranty .
Page 8: Introduction
INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations.
Page 9: Preservation Of The Environment
Polaris snowmobiles are engineered to conform to these SAE standards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others.
Page 10: 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 11: 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, on your vehicle or in this manual, alerts you to the potential for injury.
Page 12 Always check major and vital safety components before every ride. All Polaris snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.
Page 13 Operator Safety Stay Clear of 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. Be alert when riding, and remain properly seated to stay clear of the track.
Page 14: Survival Preparation
Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.
Page 15: Eye Protection
Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
Page 16: Disabled Operators
A decal on the console of these models indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only.
Page 17: Excessive Speed
Operator Safety Excessive Speed 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. Always be alert and pay attention to the trail ahead.
Page 18: 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 19 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 20: Driving Downhill
Operator Safety Ice and Snow Build-up 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 21: Driving On Slippery Surfaces
SAFETY Operator Safety Driving on Slippery Surfaces Never attempt an abrupt change of direction when operating on slippery sur- faces. 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. Slow down and use extra caution when operating on slippery surfaces.
Page 22: Drive Belt
SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do not operate the engine with the intake silencer or filter removed.
Page 23: Operating In Deep Snow
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. Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine.
Page 24: Driving Responsibly
Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile condi- tions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned driv- ers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
Page 25 Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WIND CHILL CHART (°F) Wind Speed Calm Frostbite in >> 30 min. WIND CHILL CHART (°C) Wind Speed Calm -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69...
Page 26: Clutch Cover Warning
If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
Page 27: Hot Surface Warning
HOT SURFACE - DO NOT TOUCH Burn may result. Entire top of tunnel may be hot. Install only accessories specifically approved for this model by Polaris. Track Warning The track warning decal is at the rear of the tunnel: WARNING Stay clear of track.
Page 28: Reverse Warning
Reverse Warning Operation Warning Reverse Warning Polaris snowmobiles equipped with electric reverse and will have this decal on the console: WARNING Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always: •...
Page 29: 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 30: Features
1. Front Bumper (do not use for pulling or dragging the snowmobile) 2. Hood 3. Headlight 4. Windshield 5. Handlebar 6. Fuel Filler Cap 7. Operator Seat 8. Taillights 9. Storage Compartment or Cargo Bag 10. Rear Bumper 11. Snow Flap 12.
Page 31: Features
FEATURES 1. Rider Selectt 2. Ignition Switch 3. Handlebar hook 4. Brake Lever 5. MFD (Multi-Function Display) 6. Engine Stop Switch 7. Throttle Control 8. Hood Hold Down Straps 9. Parking Brake 10. Handlebar Grip Warmer Switch 11. Thumbwarmer Switch 12.
Page 32: Cargo Area (Switchback)
FEATURES Cargo Area (Switchback) The maximum weight capacity for the cargo rack is 15 lbs. (7 kg). Always secure cargo before operating. Do not exceed the rack weight limit. Do not allow a passenger to sit on the seat back or the cargo rack. Adjustable Headlights Move the adjuster to the left to lower the headlight beam.
Page 33: Features
If your snowmobile has five adjustment positions, do not remove the RIDER SELECT lockout. Your Polaris snowmobile has been engineered for this range of adjustability. Removing this lockout and using RIDER SELECT posi- tion 6 or 7 will result in the handlebars and brake lever contacting other com- ponents and interfering with steering and braking.
Page 34: Features
RIDER SELECT Adjustable Steering System Choosing the Best RIDER SELECT Position Position Riding Style Relaxed Trail Riding Rider weight is slightly behind the center of the snowmobile for comfortable and relaxed riding. General Trail Riding, Boondocking, Deep Snow Riding Rider weight is centered on the snowmo- bile, providing balance, comfort and con- trol for both novice and experienced riders.
Page 35: Features
FEATURES RIDER SELECT Adjustable Steering System Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system. 1. Stop the snowmobile. 2.
Page 36: Features
If you are unable to determine and correct the cause of a flashing MIL or high temperature indicator, serious engine damage may occur with continued operation. See your Polaris dealer. 1. Verify that all electrical connections are secure. 2. Check battery voltage on the gauge, and install a new battery if volt- age is low (see page 48).
Page 37: Features
FEATURES Engine Management System To protect the engine, the engine management system will limit engine RPM, vehicle speed or turbo boost if the following conditions are encountered. Under extreme overheating conditions, the system will also stop the engine entirely to prevent engine damage. Vehicle Speed is Limited Cause Reverse is selected...
Page 38: 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 39: Features
FEATURES Knock Sensor A knock sensor monitors the engine and responds to detonation by auto- matically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance. NOTE: Engine performance will be reduced if fuel with a lower octane than 91 is used.
Page 40: Features
Instrumentation MFD Component Identification Item 1 Analog Gauge 2 Digital Gauge 3 Check Engine Indicator 4 High Temp Indicator 5 Brake Indicator 6 Reverse Indicator 7 High Beam Indicator Digital Display Identification Item RPM or Speed Altitude (if equipped) Service Interval Electrical System Voltage Level MAX - Maximum MPH/...
Page 41: Features
FEATURES Instrumentation MFD Settings The MFD control switch allows you to set the MFD display to your pref- erences. The rocker switch has a MODE button (top) and a SET but- MODE ton (bottom). Specific instructions are outlined on the following pages. MFD settings can be made with the engine running or with the engine off.
Page 42: Features
Instrumentation MFD Settings Speedometer/Tachometer The speedometer and tachometer can be viewed in either the analog or the digital display. If the analog display is set to show speedometer read- ings, the digital screen will automatically display the tachometer (option 1). If the analog is set to show the tachometer, the digital screen will show the speedometer (option 2).
Page 43 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 44: 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 45 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. When the hour starts flashing, press the SET switch once to advance one hour.
Page 46: 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 47 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. NOTE: Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement.
Page 48: 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 49: 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 50 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 51: 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 52: Gauge Cleaning
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. NOTE: The battery will not come out of the holder unless the leading edge of the battery is raised.
Page 53: The Perfect Fit
THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
Page 54: Front Shock Spring Preload
IQ Front Suspension Adjustments Front Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pres- sure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. To change front shock spring preload, grasp the spring and rotate it.
Page 55: Shock Valving
IQ only: The front spring rates can be adjusted by changing the nitrogen pressure. The upper chamber adjusts the main spring rate. The lower chamber adjusts preload. See your Polaris dealer for more information. Switchback only: The front springs can be changed if spring preload alone isn’t sufficient and further adjustment is desired to control suspen-...
Page 56: Suspension Performance Tips
• When riding on ice or hard-packed snow, adding a set of bogie wheels to the rail may enhance the machine's performance. Bogie wheel kits are available from your dealer. • Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated.
Page 57 THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension.
Page 58 IQ & Switchback Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To determine sag, commonly referred to as ride-in, subtract measure- ment Y from X (sag=X-Y). If the measured sag is incorrect, adjust the FRA position and/or rear torsion spring preload. Suspension Recommended Sag IQ 121 4-5 inches (10-13 cm)
Page 59: Torsion Spring Preload
THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more effort.
Page 60 IQ & Switchback Rear Suspension Adjustments Limiter Strap Position (Ski Pressure) Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter straps.
Page 61 THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Rear Shock Compression Damping (Premium Shocks) Turn the adjustment knob on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster slightly, then test ride.
Page 62: Suspension Coupling
IQ & Switchback Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of sus- pension coupling, these torque arms could move independently of each other.
Page 63 THE PERFECT FIT IQ & Switchback Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen- dent movement between the rear torque and the front torque arm.
Page 64: Weight Transfer During Acceleration
IQ & Switchback Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for control- ling weight transfer during accelera- tion is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. To decrease weight transfer under acceleration (for improved corner- ing), rotate the RRSS to a higher...
Page 65 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments The M-10 suspension has been designed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. (11 kg) or more might require appropriate changes in settings. The following information has been compiled to assist you in tuning your M-10 suspension to its maximum potential and achieve the best possible ride.
Page 66 FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings 1. To check sag, raise the rear bumper until the suspension is fully extended (the rear shock will not extend any further). Measure the distance from the ground to the bottom of the bumper (dimension X) as shown in the illustration.
Page 67: Fra Position
FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings FRA Position The FRA setting is the primary rear suspension adjustment. It will have the MOST effect on the rear suspension performance. To adjust the FRA: 1. Refer to the initial set-up reference chart (see page 67) to determine the desired FRA position.
Page 68 If FRA position alone does not allow the setup of the proper amount of sag, the center retainer of the rear track shock can be replaced with optional retainers to adjust the preload and change the sag. See your Polaris dealer for assistance. Retainer Insert Retainer Part Number...
Page 69 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter strap and front arm mount.
Page 70 FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings Ski Pressure 4. There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole increases ski pressure while the upper hole decreases ski pressure.
Page 71: Handlebar Adjustments
THE PERFECT FIT Handlebar Adjustments Use the RIDER SELECT feature to adjust handlebar position. See page 30. Use the following steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts. NOTE: If equipped, remove the mountain bar.
Page 72 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: •...
Page 73: Traction Products
Before equipping your snowmobile with traction products, be aware of the laws in your area pertaining to the use of traction products. Use only Polaris traction products on your snowmobile. Track warran- ties are void if track damage or failure results from improper or exces- sive stud installation or the use of non-Polaris traction products.
Page 74: Wear Strips
Traction Products n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control.
Page 75: Pre-Ride Inspections
Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer- enced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Drive Belt Condition Steering System Parking Brake Lock/Brake Lever/Brake System...
Page 76: Before Starting The Engine
Before Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death.
Page 77: Hood Latches
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 78: Brake Lever Travel
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 handgrip than 1/2" (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.
Page 79: Parking Brake Lever Lock
PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmo- bile to remain stationary; for example, when parked on an incline for a period of five min- utes or less.
Page 80: Before Starting The Engine
Before Starting the Engine n Track Inspection 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. Use of traction products such as studs increases the possibility of track damage and/or failure.
Page 81 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 82: Start The Engine And Check
Start the Engine and Check Engine Stop Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF. Lighting Check the headlight (high and low beam), taillight, and brake light.
Page 83: Tip-Over Inspections
Operating a snowmobile with accident damage can result in serious injury or death. Do not operate the snowmobile if vehicle components have been damaged in a collision or tip-over. Have the snowmobile inspected by an authorized Polaris dealer. CAUTION WARNING...
Page 84: Fuel Safety
Fuel Safety 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 85: Break-In Period
Break-In Period The break-in period for your new Polaris snowmobile is the first 500 miles (800 km) of operation. No single action on your part is as impor- tant as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient per- formance and longer life for these components.
Page 86: Starting The Engine
Starting the Engine Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the key to the ON position. 2.
Page 87: Emergency Starting
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 88 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 89 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 90: Fuel System Deicers
Fuel For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor- mance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85).
Page 91: Track Warm-Up
OPERATION Track Warm-Up A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throt- tle during warm-up or when the track is free-hanging.
Page 92 Track Warm-Up Follow these steps to ensure proper warm-up of the engine, drive train and track. 1. Use an appropriate stand to securely sup- port the rear of the snowmobile at the rear bumper. The track should be approxi- mately 4" (10 cm) off the ground. 2.
Page 93: Engine Stop Switch
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 illu- minated. WARNING...
Page 94: Turbo Noise
Excessive freeplay in the throttle cable may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the snowmobile to an authorized Polaris dealer for service. Turbo Noise Under some conditions, when the throttle lever is released the boost pressure dump valve will release pressure, and you may hear the sound of escaping air.
Page 95 OPERATION Electronic Reverse (PERC 4t) Electronic reverse will activate only when the vehicle is stopped and engine speed is below 2500 RPM. Maximum vehicle speed when oper- ating in reverse will be approximately 12 MPH (19 km/h). Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death.
Page 96: Emergency Stopping
Electronic Reverse (PERC 4t) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button for one second and release. The light on the instrument panel will shut off. 3. Apply the throttle slowly to make sure the snowmobile is in for- ward.
Page 97: Daily Storage
OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appro- priate track stand. The track should be suspended approximately 4" (10 cm) off the ground. Remove the key and cover the snowmobile.
Page 98: Emission Control Label
MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa- tion hangtag.
Page 99: Owner's Responsibilities
The speci- fied maintenance for the fuel filter is recommended additional emission- related maintenance. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.
Page 100: Polaris Recommended Maintenance Program
NOTE: 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. See page 110.
Page 101 MAINTENANCE Periodic Maintenance Interval Table O = Perform Service X = Replace Item Engine Stop Switch Ignition Switch Throttle Safety Switch Taillight Brakelight Headlight Skags (Wear Bars) Fluid Leaks Parking Brake Brake Lever Coolant Brake fluid Hood Latches Seat Latches Rail Slide Foam Oil Breather Element...
Page 102: Gearcase Oil Level
Periodic Maintenance Interval Table O = Perform Service X = Replace Item Coolant Hoses Heat Exchangers Fuel Lines Battery Track Tension Handlebars Drive Chain Rear Track Shock (M-10) Gearcase Oil Rear Suspension Bearings Throttle Cable Clutches Drive Belt Air Filter Oil Change Instructions (see referenced pages)
Page 103 Periodic Maintenance Interval Table O = Perform Service X = Replace Item Engine Mounts Spark Plugs Exhaust System Hoses Brake Pads/Disc Fuel Vent Lines Ski Toe Cooling Fins/Shroud Valve Lash Cooling System Fuel Filter Rear Suspension Shock Oil Instructions (see referenced pages) Inspect, replace if worn or damaged 116 Inspect condition/gap,...
Page 104: Polaris Products
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 105 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 degrees F.
Page 106 Engine Oil n Oil Level Check NOTE: 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 sys- tem before checking the oil level.
Page 107 Engine Oil n Oil Level Check 8. Maintain the oil level in the safe operating range, between the upper and lower marks on the dip- stick. If the level is low, add the recommended oil in small increments, about 2 ounces (60 ml), and recheck the level. NOTE: If the level is low, or when changing the oil, add only enough oil to bring the level to the bottom of the safe operating range on the dip-...
Page 108: Oil In System Check
5 seconds, stop the engine, and recheck for the presence of oil. 7. If no oil is present on the dipstick, check the oil system for leaks and proper operation or see your Polaris dealer. MAINTENANCE...
Page 109: Oil Change
Table beginning on page 98. Clean the foam oil breather element with each engine oil change. See page 110. Always use the recommended oil. See page 102, or see your Polaris dealer about oil change kits, which contain a new filter and the recom- mended oil.
Page 110 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 111 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 112 Engine Oil Oil Change 26. Add additional oil to bring the level slightly above the lower mark (in the safe operating range) on the dipstick. See the chart for approximate amounts to add at this step. DO NOT OVERFILL. MODEL NOTE: Check the oil level often during the fill procedure to avoid overfilling.
Page 113: Foam Oil Breather Element
Foam Oil Breather Element The foam oil breather element absorbs small amounts of liquid to pro- tect sensors within the intake system from damage due to oil ingestion. Check the element before each ride. Clean or replace the breather ele- ment at each engine oil change.
Page 114: Throttle Cable
MAINTENANCE Lubrication Driveshaft Bearing Fitting Inject grease into the fitting on the speed- ometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lightly with grease or oil.
Page 115: Rear Suspension
MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 98 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).
Page 116 MAINTENANCE Lubrication Rear Suspension M-10 128 Rear Suspension IQ 121/Switchback 136 Rear Suspension IQ 121 Shown...
Page 117: Gearcase Oil Check
Periodic Maintenance Table beginning on page Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 149 for the part numbers of Polaris products. The dipstick is located on the lower front side of the gearcase. Maintain...
Page 118: Gearcase Oil Change
Gearcase Oil Change The drain plug is located on the bottom of the gearcase. NOTE: Polaris does not recommend tip- ping the snowmobile onto it's side for service. Any time the snowmo- bile is tipped onto it's left side, always check the oil level and clean the foam oil breather ele- ment.
Page 119: 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. Using non-recommended spark plugs can result in serious engine damage. A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug.
Page 120 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. NOTE: The tip should not be white.
Page 121: Fuel Injectors
All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump. Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 98. Fuel Lines Inspect the fuel lines regularly for signs of deterioration or damage.
Page 122: Alternator Belt Inspection
Alternator Belt Inspection Inspect the alternator belt condition and tension before each ride. 1. Stop the engine. 2. Open the hood. 3. Inspect the belt for wear, cracks or other damage. If the belt is worn or damaged, install a new belt. 4.
Page 123: 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. NOTE: See page 149 for the part numbers of Polaris products. 6. Close the hood. WARNING...
Page 124: Cooling System Coolant
Contact your dealer if greater protection is required. 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 149 for the part numbers of Polaris prod- ucts. NOTE: Never add tap water to the cooling system.
Page 125 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 126: Flushing The Cooling System
To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh mix- ture of antifreeze and distilled water should be added. Have your Polaris dealer perform this service.
Page 127 Cooling System Bleeding the Cooling System 3. Open the hood. 4. Remove the coolant pressure cap carefully. 5. Slowly pour coolant into the filler neck until the coolant level reaches the bleed return hole on the inside of the filler neck.
Page 128 Cooling System Bleeding the Cooling System 9. While observing the bleed return and making sure the coolant level is visible in the filler neck, observe the engine temperature in the digital display. The temperature should rise steadily, indicating that the system is bleeding properly. 10.
Page 129: Drive Chain Tension
MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.
Page 130: Brake Components
1/16" (1.5 mm). Excessive Lever Travel Hydraulic brakes are self- adjusting, but if excessive brake pad clearance develops bring the snowmobile to an authorized Polaris dealer for inspection and adjustment. WARNING Bleed Screw Brake Disc Brake Line Brake...
Page 131: Brake Fluid
Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately. Replace brake fluid at least every two years with Polaris DOT 4 high tem- perature brake fluid. See page 149 for the part numbers of Polaris products.
Page 132: Bleeding The Hydraulic Brake System
Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever.
Page 133: Installing Halogen Bulbs
MAINTENANCE Lights Removing Halogen Bulbs 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. If fin- gers do touch the bulb, clean it with an alcohol-moistened towel. 1.
Page 134: Electrical System
Electrical System RELAY LABEL START SOLENOID RELAY CHASSIS RELAY RELAY IGNITION RELAY FUEL PUMP RELAY FAN RELAY FUSE LABEL Ground side of start solenoid SPARE 20A None ACCESSORY Accessory plugs EMERGENCY SPARE 30A High beams Low beams Handwarmers CHASSIS Thumbwarmer Tail lamp Brake lamp Alternator coils...
Page 135: Clutch Alignment Offset
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 136: 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 137: Drive Belt Removal
MAINTENANCE Clutch System Drive Belt Removal Do not attempt to remove the drive belt after operating in reverse. The snow- mobile must be stopped after forward motion to prevent damage to compo- nents during belt removal. 1. Stop the engine after operating in a forward motion. NOTE: For easier accessibility, make sure the clutch tool access hole is visible between the 11:00 and 2:00 positions of the clutch sheave.
Page 138: Drive Belt Installation
Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them.
Page 139: 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. 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 140: Track Lubrication
Track Lubrication Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for extended periods on ice and other surfaces that have lit- tle or no snow for lubrication.
Page 141: Track Tension
MAINTENANCE Track Tension Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine run- ning. Track adjustment is critical for proper handling. Always maintain cor- rect tension and alignment.
Page 142 Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic rail slide. If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7. Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the track.
Page 143: Track Alignment
35 ft. lbs. (47.5 Nm). 5. Repeat steps 2 and 3 to verify proper alignment. Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum per- missible slide thickness.
Page 144: 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 145: Ski Alignment
Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski align- ment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.
Page 146: Skag Replacement
Steering System n Ski Skags Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.
Page 147: Battery Installation
Battery Improperly connecting or disconnecting battery cables can result in an explo- sion 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 148: Battery Charging
NOTE: 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. Battery Tendert can be left connected dur- ing the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
Page 149 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 150: Battery Maintenance
Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 149 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts.
Page 151: Electrical Connections
MAINTENANCE Extended Storage Engine Protection Fogging the engine is not recommended for this model. 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 152: Polaris Products
Part No. Engine Lubricants 2874865 Performance Synthetic 4-Stroke (PS-4) 0W 50 Oil (qt.) 2874866 Performance Synthetic 4-Stroke (PS-4) 0W 50 Oil (gal.) 2876244 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (qt.) 2876245 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (gal.) Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant (qt.) 2872951...
Page 153: Troubleshooting
TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Speed, RPM or Boost is Limited Probable Cause Engine Management System RPM Reduction Mode is activated Jammed clutch Jammed track Jammed or broken chaincase sprocket or chain Mechanical failure Engine Doesn't Turn Over Probable Cause Low battery voltage Loose battery connections...
Page 154: Engine Backfires
Engine and Drive Train Troubleshooting Engine Turns Over, Fails to Start Probable Cause Out of fuel Water is present in fuel Old or non-recommended fuel Fouled or defective spark plugs No spark to spark plug Water or fuel in crankcase Clogged fuel filter Low battery voltage Poor engine compression...
Page 155 TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Runs Irregularly, Stops or Loses Power Probable Cause Engine Management System RPM Reduction Mode is activated Low battery voltage Water is present in fuel Poor quality or low octane fuel Loose ignition connections Incorrect spark plug gap or heat range Fouled or defective spark plug Kinked or plugged fuel vent line...
Page 156: Engine Overheating
Engine and Drive Train Troubleshooting Engine Overheating Probable Cause Inadequate snow conditions Low coolant Restricted air flow to radiator Harsh Drive Clutch Engagement Probable Cause Worn drive belt Excessive belt/sheave clearance Drive Belt Turns Over Probable Cause Incorrect belt Incorrect clutch alignment Broken or loose engine mount Drive System Noise Probable Cause...
Page 157 TROUBLESHOOTING IQ/Switchback Suspension Troubleshooting Problem Rear suspension bot- toms too easily Rides too stiff in rear Too much weight transfer when climb- Too little weight transfer when climb- Machine darts from side to side Front end pushes Steering is heavy Solution •...
Page 158: Suspension Troubleshooting
M-10 Suspension Troubleshooting Problem Rear suspension • Increase FRA position (see page 64). bottoms too easily • Install appropriate optional center retainer on rear track shock • Increase front track shock coil spring preload by adding • Revalve rear track shock compression damping (see your •...
Page 159: Drive Belt Wear/Burn
TROUBLESHOOTING Drive Belt Wear/Burn Cause Driving at low Drive at higher RPM. Gear the machine down. Check belt deflection. Insufficient warm- Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from the snow.
Page 160: Service And Warranty Information
Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you. When contacting us about parts, service, or warranty, always provide the following information: 1.
Page 161 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 162: 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 163: Limitations Of Warranties And Remedies
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 164: Conditions And Exclusions
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 165 • Failures caused due to improper adjustments. • Failure due to unauthorized service. • Failures due to lack of service as required in the owner’s manual or Polaris updates. This includes off-season storage as listed in the owner’s manual. • Failure due to use of unauthorized parts or modifications.
Page 166 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 167 Environmental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068. Polaris warrants that the engine is free from defects in materials and workmanship that would cause it to fail to meet these regulations. The warranty period for this emissions...
Page 168 Polaris. Owners are responsible for performing the scheduled maintenance identified in the owner's manual. Polaris can deny an emissions warranty claim if any specified critical emissions-related maintenance is not performed. Performance of other scheduled main- tenance is strongly recommended, but is not necessary to keep the emissions-related warranty valid.
Page 169: 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 (KM) 150 mi.
Page 170 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
Page 171 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
Page 172: Index
Access Panel, Radiator Compartment 29 Accessories ....69 Adjustable Steering System ..30-32 Air Filter ..... 119 Alternator Belt Inspection.
Page 173 PS-4 Oil ..... 101 Polaris Products ....149 Pre-Ride Checklist .
Page 174 Suspension Performance Tips..53 Suspension Set-up Chart, M-10 ..67 Suspension, Front ....50 Switches Stop Switch ....90 Throttle Safety Switch .

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Polaris IQ Turbo LX Owner's Manual

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