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Polaris 340 Edge Owner's Manual

Polaris 2008 snowmobile owner's manual
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  • Page 3 Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 4 Polaris enthusiasts. Be sure to visit us online at www.polarisindustries.com for the latest news, new product introduc- tions, upcoming events, career opportunities and more. Here at Polaris we proudly produce an exciting line of utility and recre- ational products. • Snowmobiles •...
  • Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 6: Table Of Contents

    Polaris Products..... . . 113 Troubleshooting ..... . . 114 Warranty .

  • Page 7: Introduction

    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 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: 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 sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.

  • Page 10: 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 11 SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track.

  • Page 12: Riding Position

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.

  • Page 13: 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 condi- tions you may encounter.

  • Page 14: Disabled Operators

    Rider Capacity Your Polaris snowmobile is designed for a single rider only. Do not carry a passenger. Excessive Speed High speed driving, especially at night, could result in serious injury or death.

  • Page 15: 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 16 Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • Take an avalanche class. • Travel with experienced people. • Travel on designated trails. • Make sure each person is equipped with a shovel, probe and avalanche beacon.

  • Page 17: Ice And Snow Build-Up

    SAFETY Operator Safety Ice and Snow Build-up Ice and snow build-up may interfere with the steering of your machine, result- ing 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 Downhill

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

  • Page 19: Driving In Hilly Terrain

    SAFETY Operator Safety Driving in Hilly Terrain Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. 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: Inadequate Snow Conditions

    SAFETY Operator Safety Inadequate Snow Conditions Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. When operating on icy surfaces or hard-packed snow, avoid overheating the slide rail and track.

  • Page 22: Driving Responsibly

    Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile condi- tions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the machine and with what it will and won't do under various conditions. Even seasoned driv- ers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
  • Page 23 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WINDCHILL CHART (_F) Wind Speed Calm Frostbite in >> 30 min. WINDCHILL CHART (_C) Wind Speed Calm -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67...

  • Page 24: Clutch Cover Warning

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

  • Page 25: Safety Decals And Locations

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

  • Page 26: Reverse Warning

    Safety Decals and Locations Reverse Warning Some Polaris snowmobiles are equipped with reverse. These models have a reverse warning decal on the lower dash.: WARNING Reverse operation, even at low speeds, can cause loss of con- trol resulting in serious injury or death.

  • Page 27: Operation Warning

    SAFETY Safety Decals and Locations Operation Warning The operation warning decal is located on the console of all Polaris snowmobiles: • To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, con- tact a Polaris dealer for a replacement.

  • Page 28: Features

    FEATURES General Representation 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Storage Compartment 7. Taillights 8. Rear Bumper 9. Snow Flap 10. Track 11. Suspension 12. Ski 13. Nosepan 14. Front Bumper (do not use for pulling or dragging the snowmobile)
  • Page 29 FEATURES Some Polaris snowmobiles are equipped with special features such as a reverse indicator light, electronic fuel gauge, temperature light and elec- tric shock control gauge. Not all models come with these features. Refer to your Owner's Manual Supplement for the features on your model.
  • Page 30 FEATURES 340 Edge 11. High Beam Indicator (340) 12. Reverse Indicator (340) 13. Low Oil Level Indicator (340) 14. Parking Brake 15. Handlebar Grip Warmer Switch 16. Thumbwarmer Switch 17. Electronic Reverse Button 18. Headlight Dimmer Switch...

  • Page 31: The Perfect Fit

    THE PERFECT FIT 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 32: Shock Components

    Shock Components The front springs can be changed if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. See your Polaris dealer for more information. 1. Retainer 2. Shock Rod 3. Jounce Bumper 4.

  • Page 33: Front Springs

    • Always adjust both shocks equally. Front Springs For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn't sufficient and fur- ther adjustment is desired to control suspension stiffness. See your Polaris dealer for more information.

  • Page 34: Front Suspension Adjustments

    Front Suspension Adjustments 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.

  • Page 35: Rear Suspension Adjustments

    A suspension set up for trail riding would bot- tom out harshly on a snowcross course. See your Polaris dealer for initial suspension setup information. Addi- tional adjustments can be made after initial setup. Make adjustments to one area at a time so you can evaluate the change.

  • Page 36: Suspension Performance Tips

    Bogie wheel kits are available from your dealer. • Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.
  • Page 37 THE PERFECT FIT EDGE Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the EDGE rear suspen- sion torsion spring preload, mea- sure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspen- sion at full extension.

  • Page 38: Torsion Spring Preload

    THE PERFECT FIT EDGE Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more effort.
  • Page 39 THE PERFECT FIT EDGE Rear Suspension Adjustments Rear Shocks Indy Select Rear Shock Your snowmobile is equipped with the Indy Select rear shock, which allows for adjustments to the compression valving. 1. Locate the adjustment screw near the base of the shock. 2.

  • Page 40: Suspension Coupling

    EDGE Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of sus- pension coupling, these torque arms could move independently of each other.
  • Page 41 THE PERFECT FIT EDGE Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen- dent movement between the rear torque and the front torque arm.

  • Page 42: Weight Transfer During Acceleration

    EDGE 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 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 the scissor stop tool located in...

  • Page 43: Handlebar Adjustments

    THE PERFECT FIT Handlebar Adjustments Handlebar Angle Follow these steps to adjust handle- bar angle at the handlebar block. 1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster block bolts (2). 2. Using a 7/16I (11 mm) wrench, loosen the four nuts (3) on the bottom of the adjuster block (turn handlebar to left or right...
  • Page 44 Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements •...

  • Page 45: Traction Products

    Use only Polaris traction products on your snowmobile. Track warran- ties are void if track damage or failure results from improper or exces- sive stud installation or the use of non-Polaris traction products.
  • Page 46 Traction Products nCarbide 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 47: Wear Strips

    THE PERFECT FIT Traction Products Wear Strips To avoid excessive tunnel wear, tunnel 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 48: Pre-Ride Inspections

    Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer- enced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Drive Belt Condition Steering System Recoil Rope...

  • Page 49: 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. Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death.

  • Page 50: Brake Lever Travel

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

  • Page 51: Parking Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1.
  • Page 52 Before Starting the Engine n Parking Brake Lever Lock Lock Release To release the lock, squeeze the brake lever tightly and release it. The lock will return to the unlocked position. If the parking brake lever lock is partially or entirely engaged while riding, the brakes may overheat, resulting in brake damage.

  • Page 53: Hood Latches

    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. WARNING...

  • Page 54: Start The Engine And Check

    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. See Before Starting the Engine beginning on page 46.

  • Page 55: Operation

    OPERATION Starting the Engine Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the fuel valve on. See page 56.
  • Page 56 Premix the first tank of fuel with one pint of Polaris injection oil for each five gal- lons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

  • Page 57: Oil Injection System

    Oil Recommendations Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends the use of Premium 2 Cycle Oil for this engine. See the table below. See page 113 for the part numbers of Polaris products.

  • Page 58: Track Warm-Up

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

  • Page 59: Fuel Valve

    OPERATION Fuel Valve Turn the fuel valve clockwise to OFF to shut off the fuel supply. Turn the valve counter-clockwise to ON to turn the fuel supply on. Fuel Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. •...

  • Page 60: Fuel System Deicers

    Fuel 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. Do not use lower than 87 octane fuel.

  • Page 61: Low Oil Indicator Light

    When the oil reaches the low level mark, add one U.S. quart of recommended oil. See page 54 for oil recommenda- tions. NOTE: The Polaris oil cap on the oil bottle is vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.
  • Page 62 Either condition may be caused by improper carburetor adjustment. Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage. Always have your Polaris dealer perform any carburetor adjustments. WARNING...

  • Page 63: Jetting Guidelines

    OPERATION Carburetion Jetting Guidelines Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. The carburetors are calibrated for an altitude of 0-2000 ft.

  • Page 64: Engine Stop Switch

    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. 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 65: Throttle Lever

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

  • Page 66: Emergency Stopping

    Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 61 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch Tether Switch (if available) WHAT IT DOES...

  • Page 67: Reverse Operation

    OPERATION Reverse Operation 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 68 Reverse Operation Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. If your machine is running at an altitude of over 6000 feet, adjust the igni- tion setting as described below. Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse.
  • Page 69 OPERATION Reverse Operation Electronic Reverse (PERCt) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running.

  • Page 70: Daily Storage

    Daily Storage At the end of each ride, park the snow- mobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approxi- mately 4I (10 cm) off the ground. Remove the key and cover the machine.

  • Page 71: Maintenance

    MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa- tion hangtag.
  • Page 72 Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.
  • Page 73 If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfort- able performing these tasks yourself, contact an authorized Polaris dealer for service. Hot components can cause damage to plastic. Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection.
  • Page 74 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 Clutch Alignment Offset...
  • Page 75 MAINTENANCE Periodic Maintenance Interval Table Item Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake Fluid Pilot Air Screws Carburetor (synchronize) Idle RPM Throttle Lever Oil Pump Lever (synchronize) Throttle Cable Choke Cable Choke Vent Lines Fuel Lines Oil Lines...
  • Page 76 Periodic Maintenance Interval Table Item Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fas- teners Suspension Shock Oil Cooling Fins and Shroud Drive Shaft Bearing Skags (Wear Bars) Ski Saddle/Spindle Bolts Ski Pivots Ski Spindle Steering Arm(s) Upper / Lower Steering Post Support Bracket Drive Chain Tension Hood Latches...

  • Page 77: Suspension And Steering

    All-Season Grease at 500 miles (800 km) and annually or every 1000 miles (1600 km) thereafter. A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmo- biles. See page 113 for the part numbers of Polaris products.
  • Page 78 MAINTENANCE Lubrication EDGE Rear Suspension...

  • Page 79: Throttle Cable

    MAINTENANCE Lubrication Jackshaft Bearing The jackshaft bearing on your model may be equipped with a grease fit- ting, but this component is greased for life at the factory. Additional lubrication is not required. Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel.

  • Page 80: Chaincase Oil

    Maintain the oil level between the “safe” marks on the dipstick. Clean the magnetic plug on the dipstick whenever checking or changing oil. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 113 for the part numbers of Polaris products.

  • Page 81: Spark Plugs

    MAINTENANCE Spark Plugs A new engine can cause temporary spark plug fouling due to the preser- vative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your machine.
  • Page 82 Spark Plugs Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be white.

  • Page 83: Intake Filters

    MAINTENANCE Intake Filters Operating the snowmobile with the intake filters removed may cause carbu- retor icing. The result will be poor fuel economy or carburetor malfunction. Always reinstall the intake filters before operating the snowmobile. 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.

  • Page 84: Oil Filter

    Fuel Filter/Fuel Lines The fuel filter is located inside the fuel tank. This component requires no maintenance. Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fuel compounds may occur. Replace worn or damaged fuel lines promptly.
  • Page 85 MAINTENANCE Carburetor Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sedi- ment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained at least every 2000 miles (3200 km) and inspected for contamination.

  • Page 86: Carburetor Adjustments

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

  • Page 87: Exhaust System

    MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.

  • Page 88: Brake Components

    Always replace brake pads when the brake pad material becomes thinner than the backing plate (approximately 1/16 Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, bring the machine to an authorized Polaris dealer for inspec- tion and adjustment. Brake Components 1. Brake Caliper 2.

  • Page 89: Brake Fluid

    Add the recommended brake fluid to bring the level up to the top of the fluid level mark on the inside of the reservoir. Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 113 for the part numbers of Polaris products.

  • Page 90: Bleeding The Hydraulic Brake System

    Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever.

  • Page 91: Headlight Adjustment

    MAINTENANCE Lights Headlight Adjustment The headlight may be adjusted for vertical aim using the following pro- cedure. 1. Place the snowmobile on a level surface with the headlight approxi- mately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall.

  • Page 92: Headlight Bulb Removal

    Lights 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. Headlight Bulb Removal 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer.

  • Page 93: Clutch System

    Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated. Do not lubricate clutch bushings.

  • Page 94: Drive Belt Condition

    Drive Belt Condition Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor perfor- mance.

  • Page 95: Drive Belt Removal

    MAINTENANCE Clutch System Drive Belt Removal Do not attempt to remove the drive belt after operating in reverse. The snow- mobile must be stopped after forward motion to prevent damage to compo- nents during belt removal. 1. Stop the engine after operating in a forward motion. 2.

  • Page 96: Drive Belt Installation

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

  • Page 97: Drive Belt Deflection

    MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pres- sure while measuring at point 2. This measurement should be 1 1/4I (3.2 cm).

  • Page 98: Tool Kit

    Maintain the proper chain tension as outlined on page 84. Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Tool Kit A tool kit is included with each machine for emergency and routine maintenance.

  • Page 99: Track Inspection

    MAINTENANCE Track Track Inspection 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 snow- mobile off the ground.

  • Page 100: Track Lubrication

    Track Track Lubrication Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for extended peri- ods on ice and other surfaces that have little or no snow for lubrication.

  • Page 101: Track Tension

    MAINTENANCE Track Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine run- ning. Track Tension Track adjustment is critical for proper handling.
  • Page 102 Track Track Tension If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the locknuts. Slack Measurement Track 10 lbs. (4.54 kg) 7. Tighten or loosen the track adjusting screws to provide equal adjust- ment on both sides of the track. 8.

  • Page 103: Track Alignment

    MAINTENANCE Track n 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. 2.

  • Page 104: Steering System

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

  • Page 105: Ski Alignment

    Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski align- ment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.

  • Page 106: Ski Skags

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

  • Page 107: Rail Slide Wear

    MAINTENANCE Steering System n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum per- missible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length.

  • Page 108: 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 113 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts.

  • Page 109: Clutch And Drive System

    MAINTENANCE Extended Storage Bearings Grease the drive shaft clutch side bearing 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. Lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant.

  • Page 110: Engine And Carburetor Protection

    (BDC), the lowest position in the cylinder. On twin cyl- inder 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 3-5 on remaining cylin- ders.

  • Page 111: Electrical Connections

    MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. 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 112: Battery Fluid

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

  • Page 113: Battery Removal

    MAINTENANCE Battery Battery Connections Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

  • Page 114: Battery Installation

    Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. Attach the hold down strap. 3.

  • Page 115: Battery Storage

    MAINTENANCE Battery Battery Storage When your snowmobile is placed in storage for one month or more: • Remove the battery. • Charge it to the proper level. • Store it in a cool dry place. • Check and/or charge monthly. •...

  • Page 116: Polaris Products

    Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid (12 oz.) 2872893 Engine Degreaser (12 oz.) 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carb and Throttle Body Cleaner POLARIS PRODUCTS Description Engine Lubricants Chaincase Lubricants Additives/Miscellaneous...

  • Page 117: Troubleshooting

    TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine oper- Drive clutch binding ating RPM during acceleration or load variations Driven clutch mal- function Harsh drive clutch Drive belt worn or...
  • Page 118 Engine Troubleshooting Problem Probable Cause Solution Noise in drive sys- Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain worn, sprocket teeth bro- Poor low RPM per- Worn drive belt formance Excessive belt/...
  • Page 119 • Make sure fuel tank contains fuel. • Ice may be in fuel line, filter or pump. Add isopropyl alcohol to fuel system. On the standard Polaris carburetor, the choke will not function with the throttle depressed. See second item under Probable Cause" of Engine Contin- ually Backfires".
  • Page 120 EDGE Suspension Troubleshooting Problem Solution Rear suspension bot- • Increase torsion spring preload toms too easily • Increase rear shock compression damping by turning • Increase torsion spring wire diameter (see your dealer) Rides too stiff in rear • Check for binding suspension shafts and grease all pivot •...

  • Page 121: Drive Belt Troubleshooting

    TROUBLESHOOTING Drive Belt Troubleshooting Causes Driving at low RPM Insufficient warm-up Towing at low RPM Riding with high RPM and slow speed (8000 RPM/10 MPH) Ice and snow build-up between track and tunnel Poor engine performance Loading machines onto trailers Clutch malfunction Slow, easy clutch engage- ment...

  • Page 122: Warranty

    Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information con- tained in this manual. Your dealer is also familiar with Polaris policies and pro- cedures and will be happy to assist you.
  • Page 123 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. Polaris warranty will aid in notifying the proper owner when a unit is recovered.

  • Page 124: 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 125: 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 126 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 127 Polaris snowmobile dealers in North America and is transfer- able 120 days after the original purchase date, free of charge, through any Polaris snow- mobile dealer. Coverage on Snow Check units is automatic. Although you do not receive a warranty card, your dealership should have printed a copy of the warranty reg- istration form.
  • Page 128 • Failures caused due to improper adjustments. • Failure due to unauthorized service. • Failures due to lack of service as required in the owner's manual or Polaris updates. This includes off-season storage as listed in the owner's manual. • Failure due to use of unauthorized parts or modifications.
  • Page 129 This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions.
  • Page 130 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 131 Environmental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068. Polaris warrants that the engine is free from defects in materials and workmanship that would cause it to fail to meet these regulations. The warranty period for this emissions...
  • Page 132 Polaris. Owners are responsible for performing the scheduled maintenance identified in the owner's manual. Polaris can deny an emissions warranty claim if any specified critical emissions-related maintenance is not performed. Performance of other scheduled main- tenance is strongly recommended, but is not necessary to keep the emissions-related warranty valid.

  • Page 133: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES TECHNICIAN (KM) 150 mi.
  • Page 134 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 135: Index

    INDEX Accessories ....41 Air Box Warning ....21 Air Pollution .
  • Page 136 Parking Brake Lever Lock ..48-49 Polaris Products ....113 Pre-Ride Checklist ....45 Pre-Ride Suspension Inspection .
  • Page 137 INDEX Track Warning ....22 Traction Products... . 42- 44 Transporting the Snowmobile ..108 Troubleshooting, Drive Belt .

This manual is also suitable for:

550 lxSupersport340 edge 2008550 lx 2008Supersport 2008

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