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Polaris 2005 Fusion 900 Owner's Manual

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  • Page 3

    WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. 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...

  • Page 5

    Copyright 2004 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 6

    S Sport Boats S RANGER utility vehicles S Victory motorcycles 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 7: Table Of Contents

    This section defines your role, and your dealer’s role, in your snowmobile’s regular maintenance. Polaris Products ......

  • Page 8: Introduction

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

  • Page 9

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

  • Page 10: Vehicle Identification Numbers

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

  • Page 11: Safety

    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 injury.

  • Page 12

    Always check major and vital safety components before every ride. All Polaris snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.

  • Page 13: Riding Position

    SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. WARNING Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track.

  • Page 14: Survival Preparation

    SAFETY Operator Safety Survival Preparation For your safety, always ride in a group of other snowmobilers. Always tell someone where you’re going and how long you expect to be gone. If it isn’t possible to ride with others, and you must travel into remote areas, always carry survival equipment that’s appropriate to the conditions you may encounter.

  • Page 15: Disabled Operators

    Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Rider Capacity Your Polaris snowmobile is designed for a single rider only. Do not carry a passenger. Excessive Speed WARNING High speed driving, especially at night, could result in serious injury or death.

  • 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

    SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: S Take an avalanche class S Travel with experienced people S Travel on designated trails S Make sure each person is equipped with a shovel, probe and avalanche beacon.

  • Page 18: Driving Downhill

    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 19: 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. Use extra caution when operating in hilly terrain.

  • Page 20: Drive Belt

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

  • Page 21

    SAFETY Operator Safety Inadequate Snow Conditions WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your machine.

  • Page 22: Driving Responsibly

    SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers.

  • Page 23

    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

    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

    SAFETY Safety Decals and Locations Track Warning The track warning decal is on the rear of the tunnel: Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death.

  • Page 26

    SAFETY Safety Decals and Locations Reverse Warning The reverse warning decal is located on the console below the windshield: Reverse operation, even at low speeds, may cause loss of control resulting in serious injury or death. To avoid loss of control, always: Look behind before and while backing.

  • Page 27

    S To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If the manual is missing, contact a Polaris dealer for a replacement. S This vehicle is capable of high speeds. Buried objects or uneven ter- rain can cause loss of control.

  • Page 28: Features

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

  • Page 29

    FEATURES 1. Fuel Filler Cap 2. Ignition Switch 3. Brake Lever 4. MFD Gauge 5. Headlight Adjuster 6. Engine Stop Switch 7. Throttle Control 8. Hood Hold Down Straps 9. Recoil Starter Handle 10. Headlight Dimmer Switch 11. Park Brake 12.

  • Page 30

    FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system allows you to adjust the handlebar position to fit your style of riding. WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death.

  • Page 31: Seat Storage Compartment

    FEATURES Seat Storage Compartment Open or close the storage compartments with the key. Adjustable Headlights Adjust the headlight beam by moving the adjuster to the left or right. Access Panel The access panel (1) is provided for cleaning out debris and making repairs.

  • Page 32

    RPM and performance. DET Troubleshooting Use this chart to determine causes and solutions for detonation. If none of these conditions exists and the sensor remains activated, see your Polaris dealer for diagnosis. Possible Cause Solution Poor quality fuel...

  • Page 33: Digital Display Identification

    FEATURES Instrumentation MFD Component Identification Item 1 Analog Gauge 2 Digital Gauge 3 Check Engine Indicator 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage...

  • Page 34: Mfd Settings

    FEATURES Instrumentation MFD Settings With the engine running, use the MFD Control Switch (1) to set the MFD display to your preference. The rocker switch has a MODE button (2) and a SET button (3). Standard vs. Metric The MFD will display either standard or metric units of measurement.

  • Page 35

    FEATURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program will remain in the display until another is selected. NOTE: The analog will always display either MPH or engine RPM (whichever setting is selected) regardless of the display program being viewed.

  • Page 36

    FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting 1. While in the CLOCK display, press and hold the SET button for five seconds. 2. When the hour starts flashing press the SET switch once to advance one hour, or press and hold the SET button to advance the hour once every 0.2 seconds.

  • Page 37

    FEATURES Instrumentation MFD Digital Display Programs Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/- -300 ft. (91 m) after adjustment. NOTE: Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement.

  • Page 38

    FEATURES Instrumentation MFD Digital Display Programs History Program The History Program automatically displays electrical system voltage level and fuel level. While in the History mode, press the SET button to view maximum vehicle speed, maximum engine rpm or the current service interval setting.

  • Page 39

    FEATURES Instrumentation MFD Digital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due. “SErVCE” will flash in the odometer area and “ENG”...

  • Page 40: Mfd Battery Replacement

    FEATURES Instrumentation MFD Battery Replacement If the clock function of the MFD isn’t working properly, replace the battery. Replacement batteries are available from your dealer. 1. Remove the plenum from the underside of the hood. 2. Locate the black battery compartment (A).

  • Page 41: Gauge Cleaning

    FEATURES Instrumentation Gauge Cleaning 1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, soft cloth. 2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution.

  • Page 42: The Perfect Fit

    THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.

  • Page 43: Shock Absorber Components

    THE PERFECT FIT IQ Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 103 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 44: Front Suspension Adjustments

    THE PERFECT FIT Front Suspension Adjustments IQ 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. A = Low preload B = High preload Increasing the spring preload too much...

  • Page 45: 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 The front springs can be changed if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness.

  • Page 46: Suspension Performance Tips

    S When riding on ice or hard-packed snow, adding a set of bogie wheels to the rail may enhance the machine’s performance. Bogie wheel kits are available from your dealer. S Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated.

  • Page 47

    THE PERFECT FIT IQ Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the IQ rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension.

  • Page 48: Torsion Spring Tension

    See your dealer for more information. 1. Soft Tension 2. Medium tension 3. Firm tension Rear Shocks Polaris Position Sensitive Shock There are no external adjustments on the Polaris position sensitive (PPS) shock.

  • Page 49: Suspension Coupling

    THE PERFECT FIT IQ Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other.

  • Page 50

    THE PERFECT FIT IQ Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm.

  • Page 51: Weight Transfer During Acceleration

    THE PERFECT FIT IQ Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting (1) is the best for most trail riding conditions. To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position with...

  • Page 52: Handlebar Position

    THE PERFECT FIT Handlebar Adjustments Handlebar Position Use the RIDER SELECT feature to adjust handlebar position. See page 27. Handlebar Angle Follow these steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster block bolts (2).

  • Page 53

    THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. The accessory tether switch is available for all models. NOTE: Order PN 2870668. Use only Polaris parts and accessories on your Polaris snowmobile.

  • Page 54

    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. See your dealer about installing studs and/or carbides. CAUTION Always install wear strips before installing studs.

  • Page 55: Wear Strips

    THE PERFECT FIT Traction Products Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control.

  • Page 56: Pre-ride Inspections

    PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. See Page See Page Item...

  • Page 57: Throttle Lever

    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. The manual is your guide to safe and enjoyable snowmobiling experience.

  • Page 58

    PRE-RIDE INSPECTIONS Before Starting the Engine Brakes Always check the ″ following items for proper (1.3 cm) operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2″ (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.

  • Page 59

    PRE-RIDE INSPECTIONS Before Starting the Engine Park Brake Lever Lock Use the park 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. 1.

  • Page 60: Steering System

    Recoil Rope Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your Polaris dealer for replacement.

  • Page 61: 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 the switch down to stop the engine. Pull it up to allow restarting. n Ignition Switch: Make sure the engine stops when the ignition switch is turned to OFF.

  • Page 62: 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. See Check Before Starting the Engine beginning on page 54. Do not depress the throttle until the engine starts.

  • Page 63: 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 64: Oil Injection System

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

  • Page 65: Track Warm-up

    OPERATION Track Warm-Up WARNING A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging.

  • Page 66

    OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel outdoors or in a well-ventilated area. S Always turn off the engine before refueling. S Do not overfill the tank. Do not fill the tank neck. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 67: Fuel Level

    Never use deicers or additives containing methanol. Polaris also recommends the use of Carbon Clean Plus. See page 109 for the part numbers of Polaris products. If you use oxygenated fuel containing ethanol, additional alcohol...

  • Page 68: Low Oil Level

    See page 61 for oil recommendations. The Polaris oil cap on the oil bottle is vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.

  • Page 69: Engine Stop Switch

    OPERATION n Engine Stop Switch Push down on the engine stop switch (A) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.

  • Page 70

    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 71: Emergency Stopping

    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 66 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit Brake Slows jackshaft...

  • Page 72

    OPERATION Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed.

  • Page 73: Daily Storage

    OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4″ (10 cm) off the ground. Remove the key and cover the machine. Towing WARNING Objects towed with a rope have no braking power and can easily...

  • Page 74: Maintenance

    MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1000 miles (1600 km).

  • Page 75: Coolant Level

    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. Frequency Page Item 150 mi.

  • Page 76: Auxiliary Shut-off Switch (engine Stop Switch)

    MAINTENANCE Periodic Maintenance Interval Table Frequency Page Item 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System 54, 87 Brake fluid FUEL MANAGEMENT...

  • Page 77: Suspension Mounting Bolts

    MAINTENANCE Periodic Maintenance Interval Table Frequency Page Item 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season CHASSIS Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Suspension Shock Oil Cooling Fins and Shroud Drive Shaft Bearings Jackshaft Bearings...

  • Page 78: Maintenance Log

    This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. 150 Mile (240 km) Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 500 Mile (800 km) Maintenance Inspection...

  • Page 79

    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 80: Front Suspension

    The Fusion front suspension and steering components do not require lubrication. Rear Suspension Lubricate the suspension pivot shafts 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 81: Chaincase Oil

    Clean the magnetic plug (B) whenever checking or changing lubricant. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 109 for the part numbers of Polaris products. Oil Check 1. Position the machine on a level surface. 2. Remove the dipstick and wipe it clean with a dry cloth.

  • Page 82: General Maintenance

    MAINTENANCE General Maintenance Spark Plugs A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Change the spark plugs every 2000-2500 miles (3200-4000 km). CAUTION Using non-recommended spark plugs can result in serious engine damage.

  • Page 83

    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 84: Fuel Pump

    Fuel Injectors All fuel injector service must be performed by an authorized Polaris dealer. Do not attempt to clean or service the fuel injectors. Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer.

  • Page 85: Oil Filter

    MAINTENANCE General Maintenance Oil Filter Inspect oil line condition at 1000 miles (1600 km). The oil filter should be changed annually or every 1000 miles (1600 km). The oil filter is located on the left side of the bulkhead behind the drive clutch.

  • Page 86: Exhaust System

    Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture. Contact your dealer if greater protection is required. See page 109 for Polaris products. NOTE: Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.

  • Page 87: Flushing The Cooling System

    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...

  • Page 88: Bleeding The Cooling System

    MAINTENANCE General Maintenance Bleeding the Cooling System Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part. WARNING Steam and hot liquids will cause serious burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot.

  • Page 89: Drive Chain Tension

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

  • Page 90: Hydraulic Brake Inspection

    MAINTENANCE General Maintenance Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. 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 91: Brake Components

    4. Brake Pad Material (Replace when thick- ness is less than 1/16″/1.5mm). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops (see page 87), bring the machine to an authorized Polaris dealer for inspection and adjustment.

  • Page 92: Brake Fluid

    Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately. Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 109 for the part numbers of Polaris products.

  • Page 93: 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 94

    MAINTENANCE General Maintenance NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Removing Halogen Bulbs 1. Remove the plenum covering from the headlight assembly.

  • Page 95: Taillight/brakelight Replacement

    MAINTENANCE General Maintenance Taillight/Brakelight Replacement 1. Open the rear storage compartment. 2. Reach into the compartment and locate the socket assembly above the door opening. 3. Turn the socket counterclockwise 1/4 turn. 4. Carefully pull the socket assembly away from the taillight.

  • Page 96: 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 clutch sheaves for damage, wear or belt residue.

  • Page 97: Drive Belt Condition

    MAINTENANCE General Maintenance Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature.

  • Page 98: Drive Belt Installation

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

  • Page 99: Drive Belt Adjustment

    MAINTENANCE General Maintenance Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4” (3.2 cm). Drive Belt Adjustment TEAM Clutch 1.

  • Page 100

    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 101

    MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods 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. 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground.

  • Page 102: Track Alignment/condition

    MAINTENANCE Track Maintenance Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the machine with the track off the ground.

  • Page 103

    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 104

    MAINTENANCE Track Maintenance Track Tension 7. Tighten or loosen the track adjusting screws (E) to provide equal adjustment on both sides of the track. 8. Repeat the measurement on the other side of the track. NOTE: Check more frequently when the machine is new. 9.

  • Page 105

    MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary.

  • Page 106: 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 107: 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 108: Suspension Maintenance

    MAINTENANCE Suspension Maintenance Slider Wear Measure slider thickness at several points along the 7/16″ rail. Have your dealer (1.1 cm) replace the slider when it’s worn down to the top of the wear groove (A). Do not operate the snowmobile if slider thickness measures less than 7/16″...

  • Page 109: Cleaning And Preservation

    Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 109 for the part numbers of Polaris products. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts.

  • Page 110: Clutch And Drive System

    MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual.

  • Page 111: Electrical Connections

    MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts. Track and Suspension Moderate track tension should be maintained during summer storage.

  • 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.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (gal.)

  • Page 113: Troubleshooting

    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 binding S SEE YOUR DEALER. operating RPM during RPM during Driven clutch S SEE YOUR DEALER.

  • Page 114

    TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch S SEE YOUR DEALER. system components Bearing failure/ S SEE YOUR DEALER. chaincase, jackshaft, or front drive shaft Drive belt surface flat S Inspect and replace as needed. spots Drive chain loose S Inspect and adjust (or replace).

  • Page 115

    TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Engine turns Faulty ignition S Install new spark plug(s). If engine still but fails to start fails to start, check for spark. If there’s no spark, SEE YOUR DEALER. No fuel to engine S Check the fuel tank level and fill with correct fuel.

  • Page 116: Suspension Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension S Adjust torsion spring preload to achieve proper static sag (see page 44). bottoms too easily S Increase rear shock compression damping (if equipped with Walker/Evans shock) (see page 44). S Increase torsion spring wire diameter to achieve proper static sag (if equipped with optional Indy Select shock) (see your dealer).

  • Page 117: Belt Troubleshooting

    TROUBLESHOOTING Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM S Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up S Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up.

  • 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 Access Panel ....Driver Awareness ....Accessories .

  • Page 125

    ......Stopping ..... . POLARIS PRODUCTS ..Storage .

  • Page 126

    INDEX Suspension Maintenance ..Track Cooling ....Suspension Performance Tips ..Track Inspection .

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