Polaris RMK 2004 Owner's Manual
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Polaris RMK 2004 Owner's Manual

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2004
2004
RMK & Switchback
RMK & Switchback
Snowmobiles
Snowmobiles
Owner's Manual
Owner's Manual
for Vehicle Maintenance
for Vehicle Maintenance
and Safety
and Safety

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Summary of Contents for Polaris RMK 2004

  • Page 1 2004 2004 RMK & Switchback RMK & Switchback Snowmobiles Snowmobiles Owner's Manual Owner's Manual for Vehicle Maintenance for Vehicle Maintenance and Safety and Safety...
  • Page 2 Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust, which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm, onto the snow on...
  • Page 3 What’s the hottest thing on snow? A Polaris owner’s Web site, designed just for YOU! Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out... www.polarisindustries.com/owner...
  • Page 4 Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 5 S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs) We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Introduction ......This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual.

  • Page 7: Introduction

    INTRODUCTION Important Notes for Owners and Drivers n After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. n The illustrations and photos used in this manual are general representations. Your model may differ. n Follow the maintenance program outlined in this manual.

  • Page 8: Preservation Of The Environment

    Polaris snowmobiles are engineered to conform to these SAE standards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others.

  • Page 9: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced.

  • Page 10: Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
  • Page 11 We strongly recommend that the operator check major and vital safety components before every ride. All Polaris snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.
  • Page 12 SAFETY Operator Safety Stay Away From Moving Parts WARNING Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious personal injury or death. We recommend having your dealer perform track service and alignment procedures.

  • Page 13: Riding Position

    SAFETY Operator Safety Riding Position WARNING Improper riding position may seriously reduce your ability to control the machine and may result in serious injury or death. Always be properly seated and in position to control your vehicle. Operating a snowmobile requires skill and balance for proper control. Rider positions may vary from person to person as each becomes more skilled;...

  • Page 14: Cargo Overload

    SAFETY Operator Safety Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier. Riding Apparel Be aware of the weather forecast and especially the wind chill.

  • Page 15: Excessive Speed

    SAFETY Operator Safety Excessive Speed WARNING High speed driving, especially at night, could result in serious personal injury or death. Always reduce speed when driving at night or in inclement weather. Observe all state and local laws governing snowmobile operation. They’ve been established for your protection.

  • Page 16: Driver Awareness

    SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts.

  • Page 17: Ice And Snow Build-Up

    SAFETY Operator Safety Ice and Snow Build-up WARNING Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering.

  • Page 18: Driving In Hilly Terrain

    SAFETY Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over.

  • Page 19: Driving Downhill

    SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine’s compression to help slow the machine and keep it from rolling freely downhill.

  • Page 20: Intake Silencer

    SAFETY Operator Safety Intake Silencer Do not operate the engine with the intake silencer or filter removed. Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds.

  • Page 21: Powder Snow Operation

    SAFETY Operator Safety Powder Snow Operation Moveable hood closures are included on some Polaris snowmobiles. They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20_F), Polaris recommends closing the upper hood closure.

  • Page 22: Driving Responsibly

    SAFETY Operator Safety Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 65 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.
  • Page 23 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART (°F) Actual Thermometer Reading (°F) Estimated Wind Speed in MPH Speed in MPH Equivalent Temperature (°F) Calm -112 -110 -124...

  • Page 24: Safety Decals And Locations

    If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.

  • Page 25: Reverse Warning

    Entanglement with the track or a fall from seat back may result in severe injury or death. Reverse Warning Some Polaris snowmobiles are equipped with electric reverse and will have this decal on the console: Reverse operation, even at low speeds, may cause loss of control resulting in serious injury or death.

  • Page 26: Operation Warning

    SAFETY Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all Polaris snowmobiles: S To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If manual is missing, contact a Polaris dealer for a replacement.

  • Page 27: Features And Controls

    FEATURES AND CONTROLS Controls 1. Fuel Filler Cap (may include a fuel gauge) 2. Ignition Switch 3. Brake Lever 4. Speedometer (may include indicator/warning lights) 5. Tachometer (may include indicator/warning lights) 6. Engine Stop Switch (see page 59) 7. Throttle Control 8.
  • Page 28 FEATURES AND CONTROLS Controls Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on this page. Not all models come with these features. Refer to your Owner’s Manual Supplement for a list of features on your machine.

  • Page 29: Features

    FEATURES AND CONTROLS Features 1. Hood 8. Snow Flap 2. Headlight 9. Track 3. Windshield 10. Suspension 4. Handlebar 11. Trailing Arm 5. Seat 12. Nosepan 6. Storage Compartment 13. Front Bumper 7. Taillights 14. Skis...

  • Page 30: Features

    FEATURES AND CONTROLS Features Detonation Elimination Technology (D.E.T.) Some Polaris snowmobiles are equipped with a detonation sensor that monitors the engine and responds to detonation by automatically reducing the engine timing. When activated, the “DETONATION FLASH” indicator (A) will flash in the lower right-hand area of the tachometer.

  • Page 31: The Perfect Fit

    THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts before fine-tuning adjustments are made. 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 32: Shock Absorber Components

    THE PERFECT FIT Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 101 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spring is set is called spring preload.

  • Page 33: Shock Damping

    THE PERFECT FIT Front Suspension Adjustments Shock Damping Adjustments to the compression stiffness of Indy Select or RydeFX SOLO shocks can be made by turning the adjustment screw (Select) or actuator (SOLO), located near the base of the shock (A). This adjustment is the easiest to perform and it should be considered first.
  • Page 34 THE PERFECT FIT Front Suspension Adjustments Adjusting Front Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. To increase front shock spring preload, grasp the spring and turn it to the right.

  • Page 35: Shock Valving

    Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a Polaris dealer. Front Springs For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn’t sufficient and...

  • Page 36: Rear Suspension Adjustments

    Bogie wheel kits are available from your dealer. S Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.
  • Page 37 THE PERFECT FIT Rear Suspension Adjustments Rear Suspension 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 this measurement with no rider and with the rear suspension at full extension.
  • Page 38 THE PERFECT FIT Rear Suspension Adjustments Rear Torsion Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information. The following information is provided only as a guideline to be used for initial suspension set-up.
  • Page 39 THE PERFECT FIT Rear Suspension Adjustments Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock. Adjustment Locate the adjustment screw (A) near the base of the shock.

  • Page 40: Handlebar With Riser Block

    THE PERFECT FIT Handlebar Adjustments Standard Handlebar Follow these steps to adjust the handlebar for a personal fit. 1. Remove the handlebar cover to access the four adjuster block bolts (A). 2. Using a 7/16″ (11 mm) wrench, loosen the four nuts on the bottom of the adjuster block (turn the handlebar either left or right for access to the rear nuts).
  • Page 41 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories.

  • Page 42: Traction Products

    Installing studs on models without wear strips will result in damage to the cooler or tunnel. Always ensure that wear strips are installed before installing studs. Always install the Polaris-approved Switchback Wear Strip Kit before installing studs on a Switchback.
  • Page 43 (2.86 cm) from the outside edge of the track. Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products.

  • Page 44: Wear Strips

    THE PERFECT FIT Accessories Wear Strips To avoid excessive tunnel or cooler damage, wear strips must be installed whenever track studding is used. See your dealer for more information. Wear strips are designed for a specific stud length. See your dealer’s studding chart for recommended traction accessories.

  • Page 45: Pre-Ride Inspections

    PRE-RIDE INSPECTIONS Before Starting the Engine WARNING Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and refer to it often. We’ve attempted to provide as much information as possible to alert you to the safety requirements of snowmobiling.

  • Page 46: Hydraulic Brakes

    88 for more information, or see your dealer for service. Replace brake fluid at least every two years. All DOT 3 brake fluid is not alike. We recommend the use of Polaris DOT 3 high temperature brake fluid. See page 110 for the part numbers of Polaris products.

  • Page 47: Before Starting The Engine

    PRE-RIDE INSPECTIONS Before Starting the Engine Park Brake Lever Lock Your snowmobile may have a park brake lever lock located over the brake lever. Use the brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less.

  • Page 48: Track Inspection

    PRE-RIDE INSPECTIONS Before Starting the Engine Check for Proper Operation of Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated.

  • Page 49: Start The Engine And Check

    PRE-RIDE INSPECTIONS Start the Engine and Check n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and start the engine. n Lighting Check: Check the headlight (high and low beam), taillight, and brake light for normal operation.

  • Page 50: Operation

    OPERATION Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. Refer to the pre-ride inspections section beginning on page 43. Starting a Cold Engine (Manual Start) Do not depress the throttle until the engine starts.

  • Page 51: Starting A Warm Engine

    OPERATION Starting the Engine Starting a Cold Engine (Electric Start) Do not depress the throttle until the engine starts. CHOKE TOGGLE POSITIONS 1. Flip choke toggle to FULL ON. 2. Pull kill switch (shut-off switch) up to RUN. 3. Turn key to START and crank engine.

  • Page 52: Engine Break-In

    No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

  • Page 53: Oil Injection System

    Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. They 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. Premium...

  • Page 54: Track Warm-Up

    OPERATION WARNING A loose track or flying debris could cause serious personal injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging.
  • Page 55 OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 56: Premium Fuel Switch

    OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used. Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane gasoline available across the country, so we encourage the use of premium fuel when possible.

  • Page 57: Fuel System Deicers

    ON/REG. The Premium Fuel light will go out. This setting will adjust the timing of your engine to run on fuels with 87 octane or higher. Polaris does not recommend using fuel with lower than 87 octane. Running your machine on ON/REG will help protect your engine from damage caused by low octane fuels.

  • Page 58: Low Oil Indicator Light

    They 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. Always maintain the oil level above the tank’s low level line. This is especially important when the machine is operated in mountainous terrain.

  • Page 59: Low Oil Level

    U.S. quart of recommended oil to the tank. See page 51 for oil recommendations. The Polaris oil cap on the oil tank may be vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.

  • Page 60: Jetting Guidelines

    In higher elevations and higher temperatures, the air is less dense. Carburetors on Polaris Switchback snowmobiles are calibrated for an altitude of 0-2000 ft. (0-600 m) and ambient temperatures between -10 to +10 F. (-23 to -12 C.). RMK carburetors are preset to operate at altitudes of 6000-9000 feet above sea level (see page 80 for more information).

  • Page 61: Engine Stop Switch

    OPERATION Engine Stop Switch Push down on the engine stop switch (A) to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position.

  • Page 62: Throttle Lever

    When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the machine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealer for service as soon as possible.

  • Page 63: Emergency Stopping

    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 59 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit Brake...

  • Page 64: Emergency Starting

    OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Machines equipped with electric start have a recoil for emergency starting. On manual start models, an emergency start strap is provided for use if the recoil starter system fails. WARNING Serious injury can result from wrapping the start strap around your hand while using the emergency starting procedure.

  • Page 65: Reverse Operation

    OPERATION Reverse Operation Electronic Reverse (PERCt) Electronic reverse will activate only if the engine is below 4000 RPM. If your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described below. Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse.

  • Page 66: Daily Storage

    The track should be suspended approximately 4″ (20 cm) off the ground. Remove the key and cover the machine. NOTE: Polaris has accessory covers and track stands available to fit all mod- els. See your dealer for more information. Towing For your safety, do not attempt to using the tow hitch until you’ve read...

  • Page 67: Maintenance

    Personal safety is critical when attempting to service or adjust your snowmobile. If you’re not familiar with safe service or adjustment procedures and the use of tools, or if you don’t feel comfortable performing these tasks yourself, contact an authorized Polaris dealer for service.

  • Page 68: Maintenance Chart

    The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer. Item Weekly or...
  • Page 69 Grease center steering arm(s) Lubricate steering post support bracket and pivot (aerosol) Check cylinder base stud torque on all Polaris engines. (Specifica- tion: 32 ft. lbs ± 2 ft. lbs.) (Dealer) Grease lower steering post pivot Flush Chaincase Grease driveshaft bearing...

  • Page 70: Maintenance Log

    This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. 150 Mile (240 km) Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 500 Mile (800 km) Maintenance Inspection...
  • Page 71 MAINTENANCE Maintenance Log Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Type of Service Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Type of Service...
  • Page 72 S Grease the steering post lower pivot. S Grease the rear suspension pivot shafts (raise the rear of unit). A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmobiles. See page 110.
  • Page 73 MAINTENANCE Lubrication The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the suspension.

  • Page 74: Throttle Cable

    MAINTENANCE Lubrication Jackshaft Bearing Greasing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps).

  • Page 75: Chaincase Oil Level

    “safe” marks on the dipstick (A). Add Polaris synthetic chaincase oil through the dipstick opening. Do not overfill. See page 110 for the part numbers of Polaris products. Flush the chaincase after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.

  • Page 76: General Maintenance

    MAINTENANCE General Maintenance Spark Plugs It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.
  • Page 77 MAINTENANCE General Maintenance Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. WARNING A hot exhaust system and engine can cause serious burns.

  • Page 78: Intake Filter

    MAINTENANCE General Maintenance Intake Filter The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. NOTE: These illustrations are general representations.

  • Page 79: Water Pump Belt Inspection

    Maintenance of the V.E.S. is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles, bring the machine to an authorized Polaris dealer to have the V.E.S. disassembled, inspected, and cleaned. NOTE: To ensure maximum performance and minimize required maintenance, follow the oil recommendation chart on page 51.

  • Page 80: Water/Sediment Trap Service

    MAINTENANCE General Maintenance Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination.

  • Page 81: Oil Filter

    Oil Filter The oil filter should be changed annually or every 1200 miles (1920 km). Inspect oil line condition at 1000 miles (1600 km). Polaris oil filters are specially designed for use on Polaris products. We strongly recommend the use of only Polaris replacement parts.

  • Page 82: Carburetor Adjustments

    It’s your dealer’s responsibility to make sure the correct main jet is installed. CAUTION Operating the snowmobile with incorrect jetting can result in serious engine damage. Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly. Carburetor Adjustments The frequency at which the carburetors are synchronized or balanced is important.

  • Page 83: Exhaust System

    MAINTENANCE General Maintenance Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage.

  • Page 84: Coolant Level

    50/50 or 60/40 mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile.

  • Page 85: Bleeding The Cooling System

    MAINTENANCE General Maintenance Engine Cooling - Liquid Cooled Models Bleeding the Cooling System If the pressure cap needs replacement, contact your dealer for the correct part. Use of a non-standard pressure cap will not allow the cooling system to function properly. WARNING Steam and hot liquids will cause serious burns to your skin.

  • Page 86: Drive Chain Tension

    MAINTENANCE General Maintenance Drive Chain Tension To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2.

  • Page 87: Hydraulic Brake Inspection

    MAINTENANCE General Maintenance Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Firmly depress the brake lever and measure the clearance between the lever and handlebar grip. This distance, called brake lever reserve (A), should be no less than 1/2″ (1.3 cm). Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16″).

  • Page 88: Brake Components

    5. Brake Pad Material (Replace when thickness is less than 1/16″). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as described on page 85, the machine should be returned to an authorized Polaris dealer for inspection and adjustment.

  • Page 89: Brake Fluid

    If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. We recommend the use of Polaris DOT 3 high temperature brake fluid. See page 110 for the part numbers of Polaris products.

  • Page 90: Bleeding The Hydraulic Brake System

    MAINTENANCE General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. 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 91: Headlight Adjustment

    MAINTENANCE General Maintenance Headlight Adjustment The headlight may be adjusted for 25’ (7.6 m) vertical aim using the following procedure: 1. Place the snowmobile on a level Lamp Center surface with the headlight Height approximately 25 feet (7.6 m) from a wall. 2″...

  • Page 92: Removing Halogen Bulbs

    MAINTENANCE General Maintenance NOTE: Avoid touching a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Removing Halogen Bulbs 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer.

  • Page 93: Clutch System

    CAUTION 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. Periodically inspect the clutch sheaves for damage, wear, or belt residue.

  • Page 94: Drive Belt Removal

    MAINTENANCE General Maintenance Periodically check the condition and tension of the drive belt, and always carry a spare belt. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. The following procedures apply to standard, electronic reverse and TEAM driven clutches.

  • Page 95: Drive Belt Installation

    MAINTENANCE General Maintenance Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack (A). NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them.

  • Page 96: Drive Belt Adjustment

    B. This measurement should be 1 1/4”. Drive Belt Adjustment Polaris Standard Clutch Belt deflection can be adjusted without removing the clutch from the jackshaft. 1. Pull the belt into the driven clutch to slightly open the sheaves.

  • Page 97: Tool Kit

    6. Flat Screwdriver 7. Shielded Screwdriver (models with Indy Select shocks) 8. Box End Wrench If necessary, a replacement tool kit may be purchased from your Polaris dealer. Chain Tension Maintain the proper chain tension as outlined on page 84.

  • Page 98: For Your Protection

    Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Maintenance Items The tools and maintenance items mentioned in this book, as well as a long line of other Polaris accessories, are available at your Polaris dealer.

  • Page 99: Track Tension

    MAINTENANCE Track Maintenance WARNING Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment is critical for proper handling.

  • Page 100: Track Alignment

    MAINTENANCE Track Maintenance f the track needs adjustment (continued): 8. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new. 9. Start machine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brakes). 10.

  • Page 101: Track Lubrication

    MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods are a serious safety hazard. They can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power.

  • Page 102: Steering System

    MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check fasteners and tighten if necessary. Specific fasteners that should be checked are marked with a in the following illustrations. Edge IFS Steering System...

  • Page 103: Ski Alignment

    Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.

  • Page 104: Ski Skags

    MAINTENANCE Steering System Ski Skags WARNING Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.

  • Page 105: Hi-Fax Wear

    MAINTENANCE Hi-Fax Wear Check Hi-fax wear by measuring the thickness at several points along the rail (A). Replace Hi-fax when a thickness of 7/16″ is reached. Take the machine to your dealer for Hi-fax replacement. If excessive Hi-fax wear occurs due to poor snow conditions, additional wheel kits are available from your 7/16″...

  • Page 106: Cleaning And Preservation

    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. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts. Wipe down remaining surfaces with a damp cloth.

  • Page 107: Controls And Linkage

    (BDC), the lowest position in the cylinder. On twin cylinder models, the opposite piston will be up. 5. Pour approximately two ounces of Polaris injector oil into the spark plug hole. 6. Wait one to two minutes and perform steps 3 to 5 on remaining cylinders.

  • Page 108: Electrical Connections

    Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. See page 110 for the part numbers of Polaris products. Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts.

  • Page 109: Battery Fluid

    MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immediate medical attention. KEEP OUT OF REACH OF CHILDREN. EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Call physician immediately.

  • Page 110: Battery Removal

    MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When cleaning is necessary, remove the corrosion with a stiff wire brush. Wash terminals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry with clean shop towels.

  • Page 111: Battery Installation

    MAINTENANCE Battery Installation WARNING Batteries contain gases that can explode. If the battery vent tube is pinched or kinked, battery gases could accumulate. Whenever removing or installing the battery, disconnect the negative (black) cable first and reinstall the negative cable last to avoid the possibility of explosion.

  • Page 112: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Oil (gal.) 2874438 VES II Synthetic 2-Cycle Oil (qt.)

  • Page 113: Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension - Verify sag dimension (see set-up decal or page 35). Adjust bottoms too easily torsion spring blocks (page 36) or install optional torsion springs to achieve correct sag dimensions. - Increase shock compression damping (page 37).
  • Page 114 TROUBLESHOOTING Belt Wear/Burn Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from the snow.
  • Page 115 TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine Drive clutch - Disassemble drive clutch to inspect shift operating RPM binding weights for wear and free operation. during accelera- SEE YOUR DEALER.
  • Page 116 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch - SEE YOUR DEALER. system components Bearing failure/ - SEE YOUR DEALER. chaincase, jack- shaft, or front drive shaft Drive belt surface - Inspect and replace if necessary. flat spots Drive chain loose - Inspect and adjust or replace.
  • Page 117 -Make sure the fuel valve is “ON”. Check tank level and fill up with correct fuel. -Ice in fuel line, filter, or pump. On the stan- dard Polaris carburetor, the choke will not function with the throttle depressed. See se- cond item under “Probable Cause” of “En- gine continually backfires”.

  • Page 118: Warranty

    2. Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. 3. Polaris warranty will aid in notifying the proper owner when a unit is recovered.

  • Page 119: 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 120: Engine Oil

    How to Obtain Warranty Service If your snowmobile requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris snowmobiles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (The cost of transportation to and from the dealer is YOUR responsibility).
  • Page 121 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 122 S Failures caused due to improper adjustments. Failure due to unauthorized service. S Failures due to lack of service as required in the owner’s manual or Polaris updates. This includes off-season storage as listed in the owner’s manual. S Failure due to use of unauthorized parts or modifications.
  • Page 123 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 124: Index

    INDEX Accessories ....39-42 D.E.T. Flash Signals ....Airbox .
  • Page 125 ....Handlebar, Standard ....POLARIS PRODUCTS ... . Headlight Adjustment .
  • Page 126 INDEX Suspension ..... Track Lubrication ....Suspension Maintenance .
  • Page 127 For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone (763) 417-8650 Fax (763) 542-0599 Part No. 9918225 Rev 03 Printed in USA...

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