Polaris AXYS PROSTAR S4 TITAN ADVENTURE 2025 Owner's Manual

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2025

For Maintenance and Safety

OWNER'S

MANUAL

PROSTAR S4 TITAN ADVENTURE

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Page 1 2025 For Maintenance and Safety OWNER’S MANUAL PROSTAR S4 TITAN ADVENTURE...
Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR Code® with your smartphone or visit: www.polaris.com/en-us/safety/...
Page 3 2025 Owner’s Manual AXYS Platform ProStar S4 TITAN ADVENTURE...
Page 4 Unless noted, trademarks are the property of Polaris Industries Inc. BatteryMINDer® is a registered trademark of VDC Electronics Inc. NGK® is a registered trademark of NGK Spark Plug Co., Ltd. SAE® is a registered trademark of Society of Automotive Engineeers, Inc. KLIM® is a registered trademark of Teton Outfitters, LLC.
Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
Page 6 WELCOME 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. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
Page 7: Table Of Contents
Specifications ....145 POLARIS Products ....149 Troubleshooting ....151 Warranty .
Page 9: Introduction
This service can be performed by your authorized POLARIS dealer. You and your authorized POLARIS dealer must complete the registration form included with your snowmobile and forward it to us. This completed form is necessary to ensure warranty coverage.
Page 10: Preservation Of The Environment
INTRODUCTION PRESERVATION OF THE ENVIRONMENT POLARIS is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment.
Page 11: Key Identification
Your key can be duplicated only by mating a POLARIS key blank using the same identification number with one of your existing keys, so if both keys are lost, the ignition switch assembly must be...
Page 12: Near-Field Communication (Nfc)
(IF EQUIPPED) Some Polaris vehicles come equipped with a near-field communication (NFC) chip. The NFC chip is embedded in the Polaris emblem located at the front of the vehicle and seamlessly connects you to a digital platform of vehicle information and tools. See your dealer for more information.
Page 13: System Requirements
INTRODUCTION 4. On the vehicle, tap the NFC-enabled badge with the phone to scan the vehicle. 5. Confirm information, name your vehicle, and tap add to garage. SYSTEM REQUIREMENTS Refer to device manufacturer’s instructions to verify NFC read capability, and/or NFC-capable add-ons.
Page 15: Operator Safety
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 16: Riding Position
SAFETY STAY CLEAR OF ENGINE Never attempt adjustments with the engine running. Turn off the ignition, open the side panels or hood, make the adjustment, secure shields and guards, secure the side panels and hood, and then restart the engine to check its operation.
Page 17: Riding Apparel
HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.
Page 18: Survival Preparation
SAFETY CLOTHING WARNING Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury. Always wear an approved helmet and eye protection. Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly.
Page 19: Driver Awareness
SAFETY EXCESSIVE SPEED WARNING High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling about 60 feet (18 m) per second.
Page 20: Disabled Operators
SAFETY DISABLED OPERATORS Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. MOUNTAINOUS TERRAIN RIDING Mountainous terrain operation, even for experienced riders, can present conditions and situations that could result in serious injury or death.
Page 21 SAFETY GET THE SAFETY GEAR In addition to carrying a spare belt, spark plugs and tools on each snowmobile, each person in your riding group should wear the recommended snowmobile riding apparel and carry (on their person) the following survival items when riding in mountainous terrain: •...
Page 22 SAFETY GET TO KNOW YOUR SAFETY GEAR Following the safety gear and apparel recommendations will increase your chances of survival if you encounter an avalanche or become stranded in the backcountry, but even experienced and properly-equipped snowmobilers, hikers and skiers perish in avalanches or succumb to hypothermia. Using a beacon or probe for the first time during an avalanche recovery operation, or not knowing how to deploy your avalanche air bag backpack during a slide, should be considered UNACCEPTABLE to you and all members of your riding group.
Page 23: Get The Picture
SAFETY GET THE PICTURE Slopes steeper than 30º are more prone to avalanches, but any slope should be considered avalanche terrain, even small slopes with trees. Low-angle slopes are also avalanche terrain if they have steeper slopes above them. NOTICE The 30º...
Page 24 • www.lavinprognoser.se for Swedish riders. • www.avalanches.org for European riders. GET AVALANCHE SAFETY TRAINING POLARIS recommends you and all members of your riding group participate in an avalanche safety course. Visit the education section of the Avalanche website for your region.
Page 25 SAFETY North American Public Avalanche Danger Scale Avalanche danger is determined by the likelihood, size and distribution of avalanches. DANGER LEVEL TRAVEL ADVICE LIKELIHOOD AVALANCHE SIZE AND AVALANCHES DISTRIBUTION Natural and Large to very Avoid all avalanche human-triggered large avalanches Extreme terrain.
Page 26: Ice And Snow Build-Up
SAFETY ICE AND SNOW BUILD-UP WARNING Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering.
Page 27: Driving Downhill
SAFETY HIDDEN OBSTRUCTIONS Always be aware of surroundings and terrain when riding your snowmobile. Hazardous obstructions may be hidden beneath the snow. Reduce speed and use extra caution whenever riding off established trails. Striking a hidden obstacle could cause loss of control of your vehicle and lead to severe injury or death.
Page 28: Drive Belt
CLUTCHES Do not attempt to service the clutches. All clutch service can be performed by your authorized POLARIS dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.
Page 29: Driving Responsibly
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 snowmobile and with what it will and won't do under various conditions. Even seasoned drivers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.
Page 30 SAFETY WINDCHILL/TEMPERATURE CHARTS The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL CHART (°F) Actual Thermometer Reading (°F) Wind -10 -15 -20 -25 -30 -35 -40 -45 Speed in MPH Equivalent Temperature (°F) Calm -10 -15 -20 -25 -30 -35 -40 -45 -11 -16 -22 -28 -34 -40 -46 -52...
Page 31: Safety Labels And Locations
If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
Page 32: Hot Surface Caution
SAFETY MOVING PARTS WARNING WARNING • Read owner’s manual. • Moving parts can crush and cut. • Keep hands clear. • Do not operate with guards or side panels removed. Part Number: 7300297 HOT SURFACE CAUTION WARNING Hot Surface. DO NOT touch. Burns may result. Part Number: 7300117 GENERAL WARNING WARNING...
Page 33: Features
FEATURES FEATURES COMPONENT LOCATIONS NOTICE The figures below are for reference only. Your model may differ slightly. Skis Fuel Cap Spindle Nosepan Operator Seat Front Suspension Shock Front Bumper Passenger Seat (if equipped) Upper Control Arm Hood Taillight Lower Control Arm Headlight Snow Flap Rail...
Page 34 FEATURES CONTROLS Brake Lever Engine Stop Switch Temporary Brake Lock Throttle Control Instrument Cluster Gear Shift Ignition Switch Handlebar Grip Warmer Thumb Warmer Switch Reverse Override Switch MODE/SET Gauge Switch Headlight Dimmer Switch...
Page 35: Gear Selector
Shifting gears with the engine speed above idle while the snowmobile is moving could cause transmission damage. Always shift when the snowmobile is stationary and the engine is at idle. Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer, can assist in resolving any shifting problems.
Page 36: Ignition Switch
FEATURES IGNITION SWITCH The ignition switch has three positions: OFF, RUN, and START. OFF Vehicle / PIDD power off RUN Vehicle / PIDD power on START Activates starter motor Turn the key to START to crank the engine. When the key is released, it automatically returns to the RUN position.
Page 37 Some rider accessories require the use of an RCA power adapter. If your model is not equipped with an RCA power plug on the handlebar cover, an accessory 12-volt RCA adapter or RCA power plug can be purchased from your POLARIS dealer.
Page 38 FEATURES ADJUSTABLE HEADLIGHT NOTICE The image below is for reference only. Your model may differ slightly. The headlight can be adjusted for vertical aim using the following procedure. 1. In a well-ventilated area, position the snowmobile on a level surface with the headlight approximately 25 ft (7.6 m) from a wall 2.
Page 39: Block Heater
FEATURES BLOCK HEATER This snowmobile is equipped with a 120 volt block heater. Use the factory-installed block heater to maintain engine coolant viscosity, prolong the life of your engine, and aid engine turnover in temperatures below 5 °F (-15 °C). To gain access to the block heater, remove the left side panel and insert the block heater plug into a grounded electrical socket.
Page 40 FEATURES L-WRENCH The L-wrench is used to open and close the driven clutch when working with the drive belt. To retrieve the L-wrench, rotate it counterclockwise and slide it upward from the bracket. When not in use, slide the L-wrench down into the bracket and rotate clockwise until it snaps securely into the housing.
Page 41 181° F (83° C) and there is no throttle lever input for 15 minutes. NOTICE If equipped with a Polaris Interactive Digital Display (PIDD), the gauge will remain on because the key is in the ON position. ECU SPEED LIMITER The ECU monitors the vehicle speed supplied by the vehicle speed sensor.
Page 43: Gauge
GAUGE GAUGE STANDARD INSTRUMENT CLUSTER Neutral Low Fuel Low Battery Voltage High Beam Low Oil Temporary Brake Lock Engine Hot Reverse Check Engine Security NOTICE Certain products will damage the lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Immediately clean off any gasoline that splashes on the instrument cluster.
Page 44: Indicator Lamps
GAUGE INDICATOR LAMPS ICON INDICATOR DESCRIPTION Check Engine This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning appears. Serious engine damage could result. Your dealer can assist. Engine Hot The over-temperature indicator will illuminate when the engine is overheating.
Page 45: Rider Information Center
GAUGE ICON INDICATOR DESCRIPTION High Beam The high beam indicator illuminates when the lights are set to high beam. Temporary The temporary brake lock indicator Brake Lock illuminates when the temporary brake lock is engaged. It will also illuminate when the service brake is in use.
Page 46 GAUGE Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. Speed Display - The speed display area displays either vehicle speed or engine speed.
Page 47: Information Display Area
GAUGE INFORMATION DISPLAY AREA This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature, maximum vehicle speed, and speed or RPM. To change the display, press and release the MODE button or the MODE switch until the desired item is displayed.
Page 48 GAUGE STANDARD/METRIC DISPLAY The odometer and temperature displays can be viewed in either standard or metric units of measurement. Both displays change if units are changed. The new settings will remain until changed by the operator. Change Method 1 1. Press and hold the center button on the instrument cluster to enter the Options Menu.
Page 49: Diagnostic Display Mode
The codes will become inactive codes if power is interrupted. Inactive codes are stored in the history of the unit. Please see your authorized POLARIS dealer who can help retrieve inactive codes.
Page 50: Speed Limiter
GAUGE SPEED LIMITER ENABLE THE SPEED LIMITER • Press and hold the Polaris button. • Press the MODE button to scroll through menu options until SPD LMT appears in the information display area. Then press the SET button. • Enter your passcode.
Page 51 NOTICE If engine overheating seems to be caused by something other than poor cooling conditions, your authorized POLARIS dealer or other qualified technician can perform a diagnosis. ENGINE-COOLING ACTIONS If the engine is overheating, promptly take action to cool the engine.
Page 52 GAUGE • Add coolant if the level is low. Do not add coolant while the engine is hot. Wait for the engine to cool before adding coolant. • If snowmobile is equipped with rail scratchers, make sure they are deployed. NOTICE If you must continue to operate while the indicator light is illuminated, drive slowly and stop the engine frequently to allow it to cool down.
Page 53: The Perfect Fit
THE PERFECT FIT THE PERFECT FIT SUSPENSION QUICK SET-UP GUIDE INTRODUCTION The front and rear suspensions on your AXYS snowmobile are easy to adjust. Just remember three simple steps: 1. Ride your snowmobile. 2. Adjust the torsion springs to tune vehicle balance (ski pressure and weight transfer).
Page 54 THE PERFECT FIT SHOCK LOCATIONS Rear Track Shock Front Track Shock Front IFS Shock SHOCK COMPRESSION DAMPING The primary adjustment for overall vehicle balance is torsion spring preload. Perform this adjustment first. After adjusting torsion spring preload to your satisfaction, compression damping adjustments can be made to control ride quality and bottoming resistance.
Page 55: Front Suspension
THE PERFECT FIT FRONT SUSPENSION INDEPENDENT FRONT SUSPENSION FACTORY SETTINGS To measure IFS shock preload, elevate the front of the vehicle and measure the length of the installed spring. SETTING PROSTAR S4 TITAN ADVENTURE Factory Installed Preload 10.25 in (26.04 cm) Minimum Installed Preload 10.6 in (26.9 cm) Clicker Setting...
Page 56: Rear Suspension
THE PERFECT FIT REAR SUSPENSION FRONT TRACK SHOCK FACTORY SETTINGS SETTING PROSTAR S4 TITAN ADVENTURE Factory Installed Preload 1.27 in (3.23 cm) Minimum Installed Preload 1.8 in (4.57 cm) Clicker Setting Medium...
Page 57 THE PERFECT FIT REAR TRACK SHOCK FACTORY SETTINGS FACTORY SETTING PROSTAR S4 TITAN ADVENTURE Clicker Setting Medium Spring Preload No Spring...
Page 58 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. Different rate torsion springs are available if a firmer ride is desired. See your authorized POLARIS dealer for more information. Soft Medium...
Page 59: Handlebar Adjustment
THE PERFECT FIT HANDLEBAR ADJUSTMENT HANDLEBAR COMPONENT FASTENER TORQUES IMPORTANT Moving a handlebar component without first loosening its screws/set screws may cut grooves into the handlebar, making it difficult to secure the component. Do not move a handlebar component without first loosening its mounting screws/set screws.
Page 60 THE PERFECT FIT TORQUE COMPONENT DO NOT OVER-TIGHTEN Not Shown Hand Guard Mounts (if applicable) Hand-Tight Not Shown Mountain Hoop Bar (if equipped) 10 ft-lbs (13.6 N·m) HANDLEBAR COMPONENT LOCATIONS Use the illustration and table below to determine the factory-set placement locations of the handlebar components.
Page 61 THE PERFECT FIT LEFT HAND CONTROL ALIGNMENT The following procedure details how to properly align the left hand control block. IMPORTANT Take care to avoid damaging hand warmer/brake switch wires when moving components. 1. Loosen the brake master cylinder mounting screws and move it away from the left hand control.
Page 62 THE PERFECT FIT THROTTLE BLOCK ALIGNMENT 1. Slightly loosen the throttle block clamp screw 2. Move the throttle block to the desired position. NOTICE Take care to avoid damaging hand warmer wires when moving components. 3. Tighten the screw to specification. Do not over-torque. TORQUE Throttle Block Clamp Screw 27 in-lbs (3 N·m)
Page 63 THE PERFECT FIT ENGINE STOP SWITCH ALIGNMENT CAUTION The stop switch must be positioned in an easily accessible location. 1. Slightly loosen the mounting screw on the bottom of the housing 2. Move the switch to the desired position. 3. Tighten the screw to specification.
Page 64: Handlebar Angle
THE PERFECT FIT HANDLEBAR ANGLE Handlebar angle can be adjusted to suit rider preference. 1. Loosen the four bolts the top riser block. 2. Adjust the handlebar upward or downward to the desired angle. Be sure the handlebar, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any...
Page 65: Pre-Ride Inspections
PRE-RIDE INSPECTIONS PRE-RIDE INSPECTIONS PRE-RIDE CHECKLIST Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined in the referenced sections. ITEM SEE SECTION Drive Belt page 113 Steering System page 67 Coolant Level page 103 Transmission Oil Level...
Page 66: Pre-Ride Suspension Inspection
PRE-RIDE INSPECTIONS ITEM SEE SECTION Track Alignment/Condition page 68 Rail Slide Condition page 131 PRE-RIDE 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.
Page 67: Before Starting The Engine
PRE-RIDE INSPECTIONS BEFORE STARTING THE ENGINE Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING Operating the vehicle with worn, damaged, contaminated, or malfunctioning components could result in serious injury or death.
Page 68 Refer to the brake bleeding information in the Hydraulic Brake Inspection section. An authorized POLARIS dealer can assist. LEVER FEEL If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See the Brake Fluid section for details.
Page 69: Lock Release
If the temporary brake lock light does not come on when the temporary brake lock or service brake is in use, have it serviced by your authorized POLARIS dealer. LOCK RELEASE To release the lock, squeeze the brake lever tightly. The lock will return to the unlocked position.
Page 70: Hood And Side Panel Fasteners
PRE-RIDE INSPECTIONS TRACK Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty. WARNING Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death.
Page 71: Start The Engine And Check
PRE-RIDE INSPECTIONS START THE ENGINE AND CHECK Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation.
Page 73: Operation
OPERATION OPERATION STARTING THE ENGINE 1. Apply brake. NOTICE Engine will not start if brake lever is not actuated. 2. Turn the key to the ON position. 3. Pull the engine stop switch up to the RUN position. 4. Turn the key to START to crank the engine. Release the key to the ON position when the engine starts.
Page 74: Track Warm-Up
OPERATION EXTREME COLD RESTARTING For better cold restarting performance, do the following after engine shutdown when the engine will be at rest for more than 2 hours and ambient temperatures fall below 0 °F (-18 °C). This procedure ensures the maximum amount of oil has been pumped from the crankcase to the external oil bottle and reduces cranking friction.
Page 75: Slide Rail And Track Cooling
OPERATION 4. Release the throttle, apply the brakes, shut off the engine and lower the snowmobile to the ground. 5. Grasp the skis by their front loops and move them from side to side to loosen snow and ice. SLIDE RAIL AND TRACK COOLING NOTICE Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure.
Page 76 Do not use fuel containing more than 10% ethanol. Never use E85 or 88 E15 fuel in your snowmobile. PROSTAR S4 MODELS 87 (R+M)/2 91 (R+M)/2 ETHANOL CONTENT Non-Ethanol Fuel with Acceptable Acceptable Polaris Anti-Static Fuel Treatment Acceptable Acceptable Unknown or Up to 10% Ethanol with Polaris Anti-Static Fuel Treatment 10% Ethanol...
Page 77: Fuel System Deicers
Polaris Recommended Engine Oil PS-4 Extreme 0W-50 Full Synthetic Engine Oil NOTICE NEVER mix oil brands or use non-recommended oil. Engine damage caused by mixing oil or using non-recommended oil may not be covered by the Polaris limited warranty. THROTTLE LEVER WARNING An improperly functioning throttle lever may cause erratic snowmobile behavior and loss of control, which could result in serious injury or death.
Page 78: Engine Stop Switch
OPERATION ENGINE STOP SWITCH Push down on the engine stop switch to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. EMERGENCY STOPPING The following chart lists methods for stopping the snowmobile in the event of an emergency.
Page 79 OPERATION TOWING For your safety, do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions. WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in serious injury or death.
Page 81: Snowmobile Break-In
Oils may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All Polaris oils are compatible with each other. Drive with extra caution during the break-in period. Perform regular checks on fluid levels, lines, and all other important areas of the snowmobile.
Page 82 SNOWMOBILE BREAK-IN Early wear can be caused by two conditions – improper track tension and/or sustained trail riding at high speeds without scratchers. Neither condition results from a defect in the track, and wear caused by either or both of these conditions is not covered by warranty.
Page 83: Maintenance
Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 (R+M)/2. If your snowmobile is equipped with a check engine light and it comes on, you must take your snowmobile to an authorized POLARIS dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician.
Page 84 Personal safety is critical when attempting to service or make adjustments to 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, your authorized POLARIS dealer can provide any needed service. WARNING...
Page 85: Pre-Season Maintenance
MAINTENANCE PRE-SEASON MAINTENANCE The chart below outlines inspection procedures that should be performed before the start of each riding season. Inspect or Adjust Air Box Bogie / Wheel Condition / Inspect or Adjust Fastener Bolts Brake Fluid Level / Leaks / Inspect or Adjust Fluid Condition Brake Hose Condition /...
Page 86 MAINTENANCE Front Limiter Strap Inspect or Adjust Inspect or Adjust Fuel / Vent Hoses Hood / Seat / Chassis / Clean if needed Engine Compartment Inspect or Adjust Oil Hoses Inspect or Adjust Rail Slide Condition Rear Idler Wheel Bolts / Inspect or Adjust Adjuster Bolt Jam Nuts Shocks / Springs...
Page 87 MAINTENANCE POLARIS MAINTENANCE SCHEDULE The intervals shown in this table are based on vehicles operated under normal conditions. Each interval is given in miles (kilometers). Service the components or systems at that interval. Continue to follow the maintenance schedule as miles/kilometers increase on the vehicle.
Page 88 MAINTENANCE Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of severe use include: constant high RPM use; prolonged low-speed or heavy load operation; extended idle; short trips. 500 MILES (800 KM) Inspect or Adjust Brake Pads / Brake Disc Replace Transmission Oil...
Page 89 MAINTENANCE Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of severe use include: constant high RPM use; prolonged low-speed or heavy load operation; extended idle; short trips. EVERY 2000 MILES (3200 KM) Replace Brake Fluid Inspect or Adjust Brake Pads / Brake Disc...
Page 90: Engine Oil
MAINTENANCE LUBRICATION REAR SUSPENSION Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table section and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).
Page 91: Oil Level Check
Check the oil level when the engine has reached an operating temperature of at least 173 °F (78 °C). Never check the oil with the engine running. Polaris Recommended Engine Oil PS-4 Extreme 0W-50 Full Synthetic Engine Oil To check the oil level, do the following: 1.
Page 92: Oil And Oil Filter Change
Engine oil is hot after use and can cause burns to skin. Always change the oil and filter according to the intervals outlined in the Polaris Maintenance Schedule on page 85. Replace the oil filter every time the oil is changed.
Page 93 MAINTENANCE 5. Drain oil from the oil reservoir. a. Hold an oil pan under the drain plug b. Use care to keep oil from spilling onto the clutch guard or clutches. c. Once oil is fully drained, re-install the oil bottle drain plug with a new washer.
Page 94 Turn by hand until filter O-ring contacts the sealing surface, then tighten an additional ¾ turn. 14. Remove the hose from the oil filter adaptor. 15. Fill the oil reservoir with the Polaris recommended engine oil. FLUID CAPACITY Recommended Engine Oil PS-4 Extreme 0W–50 Full Synthetic 4-Cycle Engine Oil...
Page 95: Side Panels
MAINTENANCE 20. Check the oil level. See page 89 for oil level check procedure. 21. Re-install the driven clutch. 22. Re-install the drive belt. See page 115 for belt installation procedure. SIDE PANELS CAUTION The hood and side panels of the snowmobile protect the operator from moving parts.
Page 96: Intake Filters
FUEL PUMP All fuel pump service must be performed by an authorized POLARIS dealer. Do not attempt to service the fuel pump. FUEL FILTER / FUEL LINES This snowmobile is not equipped with an in-line fuel filter. The fuel pump uses a sock-type pickup filter located within the fuel tank.
Page 97: Spark Plug Recommendations
• Use only resistor-type spark plugs. • Torque spark plugs to specification. • Always carry spare spark plugs. Polaris Recommended Spark Plug NGK® 95897 MR7F PN: 3022662 TORQUE Spark Plug...
Page 98: Spark Plug Removal / Installation
MAINTENANCE SPARK PLUG REMOVAL / INSTALLATION REMOVAL 1. Remove the side panels and hood. 2. Remove the upper plenum fasteners and push rivets NOTICE Image for reference only. Console configuration may vary slightly based on model.
Page 99 MAINTENANCE 3. Remove the push rivets that fasten the front intake tube to the intake plenum. 4. Remove the breather box fasteners.
Page 100 MAINTENANCE 5. Remove the intake plenum. 6. Clean the area around the ignition coils. 7. Remove the two fasteners on the each ignition coil...
Page 101 MAINTENANCE 8. Disconnect the connectors on the rear of the coils.
Page 102 MAINTENANCE 9. Carefully pull upward on both ignition coils to remove. 10. Remove both spark plugs.
Page 103: Installation
MAINTENANCE INSTALLATION 1. Set the spark plug gap to specification. MEASUREMENT NGK® 95897 MR7F Gap: 0.030 in (0.75 mm) 2. Install both spark plugs. Torque to specification. TORQUE Spark Plug: 106 in-lbs (12 N·m) NOTICE Use pre-installation tool to prevent damage to the spark plug ground strap. 3.
Page 104: Spark Plug Condition
MAINTENANCE 9. Install the upper plenum fasteners and push rivets. Torque to specification. TORQUE Upper Plenum Fastener: 88 in-lbs (10 N·m) 10. Install the hood and side panels. SPARK PLUG CONDITION NORMAL PLUG The normal insulator tip is gray, tan or light brown. There will be few combustion deposits.
Page 105: Cooling System
Do not attempt to bleed the cooling system. ProStar cooling systems require filling via the vacuum fill method and an improperly filled coolant system may cause damage to the water pump. See your authorized POLARIS dealer or other qualified technician for cooling service on your snowmobile.
Page 106: Flushing The Cooling System
FLUSHING THE COOLING SYSTEM To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added. This service must be performed when the engine is cold.
Page 107: Exhaust System
(approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake pads. Your POLARIS dealer can assist. WARNING Brake failure during operation can result in serious injury or death. Properly functioning brakes are vital to your safety. Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive.
Page 108: Brake Components
The lightweight brake discs have vent holes that may cause a high-pitched sound during operation. BRAKE FLUID Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid, or an equivalent product. WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.
Page 109: Bleeding The Hydraulic Brake System
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. WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death.
Page 110: Fuse Replacement
MAINTENANCE LIGHTS The headlight and taillight assemblies feature LED elements and are not serviceable. If an LED fails to illuminate in either the headlight or taillight, the entire assembly must be replaced. FUSE REPLACEMENT If the engine stops or will not start, or if an electrical component fails to operate, a fuse may need replacement.
Page 111 MAINTENANCE LOAD CENTER DETAILS CIRCUIT FUNCTION Coil Low Relay In Fan Relay Relay Out Coil High Coil Low Relay In Fuel Pump Relay Relay Out Coil High Coil Low Relay In Relay Start Relay Out Coil High Coil Low Relay In EFI Relay Relay Out Coil High...
Page 112 MAINTENANCE CIRCUIT FUNCTION Power In Power Out Start 10A Fuse Power In Power Out MAG Coil 5A Fuse Power In Power Out PTO Coil 5A Fuse Power In Power Out Fuel Pump 10A Fuse Power In Power Out Fan CB 10A Fuse Power In Coil Low —...
Page 113 MAINTENANCE SPARE BELT HOLDER REMOVAL The spare belt holder attached to the clutch guard. Use the following procedure to remove the spare belt holder from the snowmobile. 1. Open the left compartment door panel. 2. Rotate the 1/4 turn fastener at the top of the spare belt holder.
Page 114: Clutch System
POLARIS dealer. Any unauthorized modifications to clutches, such as adding or removing weights, may void the warranty. NOTICE The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated. Do not lubricate clutch bushings. CLUTCH ALIGNMENT OFFSET Clutch alignment offset is important for maintaining optimum performance.
Page 115: Drive Belt Condition
MAINTENANCE DRIVE BELT CONDITION Periodically check the condition and tension of the drive belt. 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. See page 155. Always carry a spare drive belt.
Page 116 MAINTENANCE 8. Turn the wrench clockwise until the sheaves open far enough to remove the belt. 9. Firmly grasp the belt midway between the clutches and pull upward and rearward to remove it from the driven and then drive clutch.
Page 117: Drive Belt Installation
NOTICE Always clean the drive belt using a mixture of warm, soapy water. Allow to air dry. When installing the belt, verify POLARIS or the part number can be read from the outside of the snowmobile. 1. Verify the driven clutch sheaves are open. If they are not, install the L-wrench and open the sheaves.
Page 118 MAINTENANCE 5. Reinstall the wrench to the wrench bracket to secure the fender to the console. 6. Install the spare belt holder. 7. Reinstall the side panel. 8. When installing a new belt, follow the belt break-in procedures.
Page 119: Drive Belt Deflection Inspection
MAINTENANCE DRIVE BELT DEFLECTION INSPECTION Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt and apply 4 pounds of downward pressure while measuring at point. This measurement should be 1/2 inch (12.7 mm). MEASUREMENT Belt Deflection: 0.5″...
Page 120: Drive Belt Deflection Adjustment
MAINTENANCE DRIVE BELT DEFLECTION ADJUSTMENT NOTICE Proper drive belt deflection is an important factor for good transmission shifting performance. Make sure the drive belt deflection is set to specification. Belt Deflection: 0.5” (12.7mm) 1. Loosen the 7/16 in. jam nut on the belt width adjuster screw. 2.
Page 121: Driven Clutch Removal
MAINTENANCE DRIVEN CLUTCH REMOVAL To access the Driven Clutch, remove the left side panel. 1. Remove the drive belt. See page 113 for drive belt removal procedure. 2. Lock the temporary brake lock. NOTICE If the transmission is in Neutral the driven clutch will spin with the temporary brake lock on.
Page 122 MAINTENANCE 5. Remove the shim from the jackshaft. 6. Remove the movable sheave from the jackshaft. 7. Inspect the jackshaft and driven clutch splines for damage. Replace components as required.
Page 123: Drive System
MAINTENANCE DRIVE SYSTEM TRANSMISSION FLUID CHANGE The drain plug is located on the bottom of the right side of the transmission. Access the drain plug using the following procedure. 1. Position vehicle on a level surface. 2. Remove the right side panel. 3.
Page 124 MAINTENANCE 5. Remove the fasteners securing the rear of the right fender to the footrest support. 6. Carefully flex the right fender downward to gain access to the drain plug.
Page 125 MAINTENANCE 7. Remove the fill plug 8. Place a drain pan under the transmission drain plug. 9. Remove the drain plug and allow fluid to drain completely. NOTICE Fluid may run down the fender before draining into the drain pan. Once fluid has drained completely, wipe up any residual fluid on the fender.
Page 126: Track Maintenance
MAINTENANCE 13. Reinstall the fill plug and torque to specification. TORQUE Transmission Fill Plug 12 ft-lbs (16 N·m) 14. Check for leaks. Dispose of used fluid properly. TRACK MAINTENANCE WARNING Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts.
Page 127: Track Lubrication
If excessive rail slide wear occurs due to poor snow conditions, additional wheel kits are available. Your authorized POLARIS dealer can provide more information. Track damage or failure caused by operation on ice or under other poor lubrication conditions may void the track warranty.
Page 128: Track Tension
MAINTENANCE 3. Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side. If the track runs to the left, loosen the idler shaft bolt, then loosen the left locknut and tighten the left adjusting bolt.
Page 129 TORQUE Idler Shaft Bolt 55 ft-lbs (75 N·m) STEERING SYSTEM The steering systems on POLARIS snowmobiles can be adjusted with ski toe alignment. Improper toe alignment can cause erratic steering. Your authorized POLARIS dealer can assist with adjustments. WARNING Improper alignment or adjustment may cause loss of steering control, resulting in serious injury or death.
Page 130: Front Suspension Inspection
FRONT SUSPENSION INSPECTION WARNING Improper fastener torque or front suspension component damage may cause loss of steering control, resulting in serious injury or death. Your POLARIS dealer can assist. Each week, or before a long ride, check the following items. If component damage or loose fasteners are found, your POLARIS dealer can provide service.
Page 131: 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 alignment or camber adjustment. Your authorized POLARIS dealer can assist. To align skis, do the following: 1.
Page 132: Ski Skags
MAINTENANCE SKI SKAGS WARNING Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. Your dealer's studding chart can provide the 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 133: Rail Slide Wear
Ski Skag Fasteners 8 ft-lbs (11 N·m) RAIL SLIDE WEAR Polaris rail slides run along the bottom of the rail to prevent track wear. The rail slide should be inspected periodically and replaced when necessary. For ease of inspection, all...
Page 134: California Proposition 65 Warning
MAINTENANCE BATTERY WARNING CALIFORNIA PROPOSITION 65 WARNING: Batteries, battery posts, terminals and related accessories can expose you to chemicals including lead, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to www. P65Warnings.ca.gov.
Page 135 MAINTENANCE LEAD ACID CONVENTIONAL AND DRY SHIPPED AGM BATTERIES These batteries are characterized by the following features: • Battery is NOT activated when packaged • Removable cap plugs and strip are found top-side of the battery • Lead Acid Conventional batteries ONLY: –...
Page 136: Battery Removal
MAINTENANCE BATTERY REMOVAL WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When re-installing the battery, always connect the negative (black) cable last. 1.
Page 137: Battery Installation
MAINTENANCE BATTERY INSTALLATION When installing a new battery, ensure it has a full charge prior to initial use. Using a new battery with a partial charge can damage the battery, cause shorter battery life, and hinder vehicle performance. Follow the charging instructions, included with your new battery, before installing.
Page 138: Battery Charging
MAINTENANCE 8. Route the harness ground wires , main battery ground cable , and positive (red) battery cable as shown in the image. Both are routed up and over the rubber strap. If the ground wires/cable are routed down the side of the battery, they may interfere with the tab of the rear side panel.
Page 139 MAINTENANCE 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 using the battery charge port.
Page 140: Battery Maintenance
The battery provides power for only the following purposes: • Engaging the electric starter motor to start the engine • Powering the Polaris Interactive Digital Display (PIDD) with the ignition key when the engine is off • Powering electrical accessories (winch, passenger seat heaters, etc.)
Page 141: Battery Type
MAINTENANCE Never store a battery in a partially charged condition or hard, crystal sulfation will form on the plates resulting in reduced efficiency and shorter service life of the battery. If you do not drive the vehicle for more than TWO weeks, maintain Absorbent Glass Mat (AGM) batteries with the BatteryMINDer®...
Page 142 2. When performing the summerization storage procedures, fill the fuel tank completely with the recommended fuel. 3. Treat the fuel in the fuel tank with the recommended amount of Polaris Carbon Clean (E10 fuel) or Polaris Anti-Static Fuel treatment (<E10 fuel) as the fuel stabilizer.
Page 143 MAINTENANCE 1. Remove the spark plugs from the engine. 2. Liberally spray fogging oil into each spark plug hole. 3. Loosely install the spark plugs. NOTICE Do not install new spark plugs after fogging the cylinders. Fogging oil prevents the formation of rust / corrosion by sticking to the internal engine components – including the spark plug electrodes.
Page 144 Do not spray metal protectant on the drive or driven clutches. LUBRICATE THE PIVOTS After washing the snowmobile, it is important to use Polaris Premium All Season grease to lubricate the various suspension / steering pivot points. Doing so forces any water accumulated within the joints out which prevents the formation...
Page 145 MAINTENANCE 1. Use a grease gun and Polaris Premium All Season Grease. Reference the appropriate Owner’s Manual to locate any / all grease zerks on the steering and suspension systems. 2. Pump fresh grease into all zerks until the grease can be seen purging out of each joint.
Page 146 10. With the track suspended up, off the ground, follow the track tension adjustment procedure as outlined in your owner’s manual. 11. Treat the fuel in the fuel tank with the recommend amount of Polaris Carbon Clean (E10 fuel) or Polaris Anti-Static Fuel treatment (<E10 fuel) as the fuel stabilizer.
Page 147: Specifications
SPECIFICATIONS SPECIFICATIONS PROSTAR S4 TITAN CAPACITIES AND DIMENSIONS Body Style Axys Rider Capacity Adventure Models: 2 riders Coolant Capacity 8.2 qt (7.8 L) Fuel Tank Capacity 13.5 gal (51 L) Gearcase Oil Capacity 23.6 oz (700 mL) Oil Capacity 3.7 qt (3.5 L) Estimated Dry Weight 722 lb (327 kg) Height...
Page 148 SPECIFICATIONS ENGINE AND COOLING Engine S8810-0999-LR-LI9F Displacement 998 cc Cylinders Bore x Stroke (mm) 93 x 73.5 Alternator Output 565 w @ 5,000 RPM Throttle Body 2414637 Throttle Body Bore Size (48 mm) Recommended Engine Oil PS-4 Extreme 0W-50 4-Cycle Oil Idle RPM (at operating temperature) 1250 +/- 200 Rated Operating RPM...
Page 149: Clutching Chart
SPECIFICATIONS CLUTCHING CHART CLUTCH SETTINGS DRIVE CLUTCH DRIVEN CLUTCH ALTITUDE meters (feet) Shift Weight Clutch Spring Clutch Spring Driven Helix 15-76 0-900 (0-3000) (1327216) 15-74 900-1500 (3000-5000) (1327215) 15-72 1500-2100 (5000-7000) (1327140) 55/155 180/240 42 Straight (7045869) (7045922) (3236113) 15-70 2100-2700 (7000-9000) (1327214) 15-68...
Page 151: Polaris Products
2882201 Oil - Polaris Blue SYN qt. (12) 2882202 Oil - Polaris Blue SYN gal. (6) 2882204 Oil - Polaris Blue SYN 2.5 gal. (2) Gearcase/Transmission Lubricants 2873105 SCL - Synthetic Chaincase Lubricant qt. (.95 l) 2873106 SCL - Synthetic Chaincase Lubricant gal (3.8 l)
Page 153: Engine Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ENGINE TROUBLESHOOTING Unless you have experience and training in four-cycle engine repair, your dealer can assist if technical problems arise. PROBLEM PROBABLE CAUSE SOLUTION Erratic engine Drive clutch binding Your dealer can perform operating RPM this service. during Driven clutch malfunction Your dealer can perform acceleration or...
Page 154 TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Drive chain loose Inspect and adjust (or replace). Drive chain worn, Your dealer can perform sprocket teeth broken this service. Poor low RPM Worn drive belt Inspect and replace as performance needed. Excessive belt/sheave Your dealer can perform clearance this service.
Page 155 TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Engine turns but Faulty ignition Install new spark plug(s). If fails to start engine still fails to start, check for spark. If there's no spark, Your dealer can perform this service. No fuel to engine •...
Page 156: Suspension Troubleshooting
TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Engine requires Poor fuel Replace with fresh winter more than normal fuel. cranking time to Not enough fuel getting to Your dealer can perform start engine this service. Plugged fuel filter or tank Your dealer can perform pick-up sock this service.
Page 157 TROUBLESHOOTING PROBLEM SOLUTION Too little weight Refer to the Suspension Quick Set-Up Guide for transfer when climbing details. Machine darts from • See your dealer for ski alignment inspection. side to side • Make sure spindles and all steering components turn freely.
Page 158 TROUBLESHOOTING BELT WEAR/BURN DIAGNOSIS CAUSES SOLUTIONS Riding with high RPM Lower the gear ratio. Reduce RPM. Avoid riding in and slow speed (8000 high ambient temperatures. Check for snow RPM/10 MPH/16 km/h) ingestion. Ice and snow build-up Warm the engine at least five minutes. Take the between track and drive belt off the snowmobile in extremely cold tunnel...
Page 159: Warranty
Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual. Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you.
Page 160: Limited Warranty
REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage.
Page 161: Warranty Coverage And Exclusions
WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS Limited Warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
Page 162: How To Obtain Warranty Service
TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW. HOW TO OBTAIN WARRANTY SERVICE You are responsible for presenting your vehicle to an authorized POLARIS Dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. However any damage caused to the product by you or any non-authorized third party may void this warranty.
Page 163 IF YOU PURCHASE FROM A PRIVATE PARTY: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. However, we encourage you to register your product at a local authorized POLARIS dealer promptly to receive safety information and notice regarding your product.
Page 164 IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have any questions.
Page 165 U.S.A. EPA EMISSIONS LIMITED WARRANTY This Emissions Limited Warranty is in addition to the POLARIS standard Limited Warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
Page 166 POLARIS. Owners are responsible for performing the scheduled maintenance identified in the owner’s manual. POLARIS may deny warranty claims for failures that have been caused by the owner’s or operator’s improper maintenance or use, by...
Page 167 POLARIS also recommends that you use only POLARIS parts, however, equivalent parts may be used for such service. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle’s emission controls.
Page 169: Maintenance Log
MAINTENANCE LOG MAINTENANCE LOG Present this section of your manual to your authorized POLARIS dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile.
Page 170 MAINTENANCE LOG SERVICE PERFORMED / DATE HOURS TECHNICIAN COMMENTS...
Page 171 INDEX 12-Volt RCA Power Sources ..35 Clutch Safety ......26 Clutch System ......112 Clutching Chart ProStar S4 Titan....145 Cold Weather Drive-Away ... 26 Air Pollution........ 8 Component Locations....31 Avalanche Controls ........32 Awareness ......22 Coolant ......... 103 Avalanche Danger Scale .....
Page 172 INDEX Engine Stop Switch ....69, 76 Handlebar Angle ....... 62 Engine Stop Switch Alignment..61 Handlebars Engine-Cooling Actions....49 Component Locations....58 Environment Preservation ..... 8 Fastener Torques ....57 Exhaust System ...... 105 Headlight ......... 36 Exported Products ....162 Helmet ........
Page 173 Overheating, Engine ....49 Spare Belt Holder ...... 38 Removal ......111 Spark Plug Removal Installation ......96 Polaris Products ...... 149 Spark Plug Condition....102 Pre-Ride Checklist ..... 63 Spark Plug Recommendations ..95 Pre-Ride Inspection Spark Plugs......95 Suspension ......
Page 174 INDEX Standard/Metric Display ....46 Transmission Starting the Engine ....71 Fluid Change ....... 121 Steering System....127-128 Transporting the Snowmobile ..139 Steering System Inspection ..67 Treating the Fuel System ..140 Stopping the Snowmobile Troubleshooting, Drive Belt..155 Emergency Stop.....
Page 176 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Inc. 2100 Highway 55 Part No. 9941964 Rev 01 Printed in USA Medina, MN 55340...