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. 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 which they operate.
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. RIDER SELECT is a trademark of Polaris Industries Inc. M-10 is a registered trademark of FAST Inc. Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication.
Page 6: Table Of Contents
Polaris Products..... . . 132 Troubleshooting ..... . . 133 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 wel- come 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. 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 12: Riding Position
Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmobiles, but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.
Page 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
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 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 WARNING 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 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: Inadequate Snow Conditions
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. WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury.
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: Track Warning
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. "No Passenger"...
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: Safety Decals And Locations
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
1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Storage Compartment/Trunk 7. Taillights 8. Rear Bumper 9. Snow Flap 10. Track 11. Suspension 12. Ski 13. Nosepan 14. Front Bumper 15. Adjustable Seat Bucket (select models) FEATURES...
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 machine.
Page 30: Det Troubleshooting
Do not modify the engine Use the correct jetting for your altitude Cause Detonation See DET Troubleshooting Chart Faulty sensor See your Polaris dealer High water See your Polaris dealer. NOTE: temperature If temporary operation is unavoidable, drive slowly and stop the engine frequently to allow the engine to cool.
Page 31: Seat Bucket Adjustment
FEATURES Adjustable Seat Bucket On models equipped with an adjustable seat bucket (1), the bucket can be adjusted for- ward or rearward for rider comfort. The seat bucket is removable for access to the under-seat storage compart- ment. Do not sit on the seat bucket. Do not operate the snowmobile with the seat bucket removed.
Page 32: Trunk Lock
(1). Use the trunk lock keys to lock or unlock the under-seat storage compartment. If keys are lost or misplaced, see your Polaris dealer. When the trunk is locked, the lock cannot be pressed in and the seat bucket cannot be removed.
Page 33: 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 34: 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 35: Shock Damping
THE PERFECT FIT Front Suspension Adjustments Shock Damping Adjustments to the compression stiff- ness 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 (✪). This adjustment is the easi- est to perform and it should be consid- ered first.
Page 36: 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 37: Shock Valving
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 fur- ther adjustment is desired to control suspension stiffness. See your Polaris dealer for more information.
Page 38: Rear Suspension Adjustments
Refer to the suspension setup label on your snowmobile, or see your Polaris dealer for initial suspension setup information. Additional adjustments can be made after initial setup. Make adjustments to one area at a time so you can evaluate the change. For further assistance, see...
Page 39: 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 40 EDGE Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the EDGE rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement Take the first measurement with no rider and with the rear suspension at full extension.
Page 41: Torsion Spring Tension
THE PERFECT FIT EDGE Rear Suspension Adjustments 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. See your dealer for more information. Soft Tension Medium Tension Firm Tension...
Page 42 THE PERFECT FIT EDGE Rear Suspension Adjustments Rear Shocks 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 adjust- ment screw located near the base of the shock. Locate the adjustment screw near the base of the shock.
Page 43 EDGE Rear Suspension Adjustments Rear Shocks Polaris Position Sensitive Shock There are no external adjustments on the Polaris position sensitive (PPS) shock. There is a performance PPS shock kit available for increasing damping, however. If you desire to have the internal valving changed, consult your dealer, or refer to the suspension troubleshooting decal located under the hood or on the clutch guard.
Page 44: 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 45 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 46: 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 condi- tions. To decrease weight transfer under acceleration (for improved corner- ing), rotate the RRSS to a higher position with the scissor stop tool...
Page 47 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments The M-10 suspension has been designed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. (11 kg) or more might require appropriate changes in settings. The following information has been compiled to assist you in tuning your M-10 suspension to its maximum potential and achieve the best possible ride.
Page 48 FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings 1. To check sag, raise the rear bumper until the suspension is fully extended (the rear shock will not extend any further). Measure the distance from the ground to the bottom of the bumper (dimension X) as shown in the illustration.
Page 49 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings FRA Position The FRA setting is the primary rear suspension adjustment. It will have the MOST effect on the rear suspension performance. To adjust the FRA: 1.
Page 50 FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings Rear Spring Preload The top section of the crossover tube (the tube at the top of the rear shock) has a threaded collar on it. The rear spring has a lock tab that fits into the collar to allow easy spring preload adjustment.
Page 51 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Other Ride and Performance Settings Overload Spring The overload spring is located inside the main rear spring. Contact is made with this spring only when the crossover tube comes in contact with it toward the end of the travel, which reduces bottoming of the rear suspension.
Page 52 Front Arm Firm Rear Arm Standard Rear Arm Soft Rear Arm Firm Overload THE PERFECT FIT SPRING RATE 160 lbs./in. 140 lbs./in. 180 lbs./in. 210/278 lbs./in. 135/240 lbs./in. 300 lbs./in. 1000 lbs./in. POLARIS PN 7041671-216 7041677-067 7041672-067 7041935-216 7042010-216 7042011-067 7041936-067...
Page 53 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Other Ride and Performance Settings Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter strap and front arm mount.
Page 54 FAST M-10 Rear Suspension Adjustments Initial M-10 Suspension Set-up Chart NOTE: These positions are only preliminary. Experimentation should follow initial set-up to obtain optimum results. Refer to the sus- pension troubleshooting decal for additional set-up tips. INITIAL SET-UP REFERENCE CHART This chart is a guideline to be used for initial suspension set-ups.
Page 55: Handlebar Adjustments
THE PERFECT FIT Handlebar Adjustments Handlebar Angle Follow these steps to adjust handlebar angle at the handle- bar 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...
Page 56 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 57: 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 58 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 59: 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. Some models are manufactured with tunnel wear strips or wear strip coolers installed.
Page 60: 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 61: Before Starting The Engine
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 62: 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 63: Park Brake Lever Lock
PRE-RIDE INSPECTIONS Before Starting the Engine n 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 64: Steering System
Before Starting the Engine n Steering System WARNING 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 65: Hood Latches
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. n Transmission Make sure the transmission is not in reverse before starting the engine...
Page 66: Start The Engine And Check
Start the Engine and Check Engine Stop Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF. Tether Switch If your machine has a tether switch, remove the tether from the switch to make sure the engine stops immediately.
Page 67: 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 Before Starting the Engine beginning on page 58. 1.
Page 68: Engine Break-In
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 69: Oil Injection System
Engine lubrication comes from oil added to the fuel and oil injection systems. On Polaris snowmobiles equipped with a variable exhaust sys- tem (VES), Polaris highly recommends the use of only VES II 2 Cycle Oil. See the table below for additional oil recommendations. See page 132 for the part numbers of Polaris products.
Page 70: Track Warm-Up
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 throt- tle during warm-up or when the track is free-hanging.
Page 71: 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 WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline.
Page 72: Premium Fuel Switch
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 73: Fuel System Deicers
RES. Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures.
Page 74: Low Oil Indicator Light
U.S. quart of recommended oil. See page 66 for oil rec- ommendations. NOTE: The Polaris oil cap on the oil bot- tle is vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.
Page 75 Either condition may be caused by improper carburetor adjustment. WARNING Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage. Always have your Polaris dealer perform any carburetor adjustments.
Page 76: Jetting Guidelines
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 77: Engine Stop Switch
OPERATION Engine Stop Switch Push down on the engine stop switch (✪) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. 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 78: 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. OPERATION...
Page 79: Emergency Stopping
OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 74 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 (Option) WHAT IT DOES...
Page 80: Emergency Starting
Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Snowmobiles equipped with electric start have a recoil for emergency starting. On non-electric-start models, if the recoil starter system fails, an emergency start strap is provided in the kit. 1.
Page 81: Reverse Operation
OPERATION Reverse Operation 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 82 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 83: Altitude Setting
OPERATION Reverse Operation Electronic Reverse (PERCt) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button for one second and release. The engine will slow and begin to rotate forward. The light on the instrument panel will shut off.
Page 84: 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 approximately 4I (10 cm) off the ground. Remove the key and cover the machine. Towing For your safety, do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions.
Page 85: Maintenance
MAINTENANCE Emission Control Information (340cc and 600cc Engines Only) 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. These items are required by U.S. Environmental Protection Agency regulations.
Page 86 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 87 Personal safety is critical when attempting to service or make adjust- ments to your snowmobile. If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfort- able performing these tasks yourself, contact an authorized Polaris dealer for service. CAUTION Hot components can cause damage to plastic.
Page 88 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 89: Auxiliary Shut-Off Switch (Engine Stop Switch)
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 Throttle Position Sensor...
Page 90: Suspension Mounting Bolts
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 Jackshaft Bearings Skags (Wear Bars) Ski Saddle/Spindle Bolts Ski Pivots Ski Spindle Steering Arm(s) Upper / Lower Steering Post Support Bracket Drive Chain Tension...
Page 91 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 132 for the part numbers of Polaris products.
Page 92 MAINTENANCE Lubrication EDGE Rear Suspension ✪ ✪ ✪ ✪ ✪ M-10 Rear Suspension ✪ ✪ ✪ ✪...
Page 93 MAINTENANCE Lubrication Other Rear Suspensions ✪ ✪ ✪ ✪ ✪ ✪ ✪ ✪ ✪ ✪ ✪ ✪ ✪ ✪...
Page 94: Throttle Cable
MAINTENANCE Lubrication Jackshaft Bearing ✪ Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fit- ✪ ting. 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 95: 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 132 for the part numbers of Polaris products.
Page 96: General Maintenance
General 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 97 MAINTENANCE General Maintenance Spark Plugs 1. Normal The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white.
Page 98: Intake Filters
✪ Fuel Filter/Fuel Lines See your Polaris dealer for replacement of the in-tank fuel filter every 1000 miles (or annually). 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.
Page 99: Oil Filter
1500 miles (2400 km). Inspect belt width (✪) and condition, and replace if cracked or worn past the width service limit (.250I / 6.35 mm). New belt width is approxi- mately .345I (8.75 mm). See your Polaris dealer if the belt needs to be replaced.
Page 100: Water/Sediment Trap Service
General Maintenance 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 101: Carburetor Adjustments
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 102: Exhaust System
Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/ 40% water mixture. See page 132 for the part numbers of Polaris prod- ucts. 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 103: Coolant Level
This service must be performed when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile.
Page 104: Bleeding The Cooling System
General Maintenance Bleeding the Cooling System 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. Use of a non-standard pressure cap will not allow the recovery system to function properly.
Page 105: 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 106: 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 107: 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 3 high temperature brake fluid. See page 132 for the part numbers of Polaris products.
Page 108: Bleeding The Hydraulic Brake System
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 109: Headlight Adjustment
MAINTENANCE General Maintenance 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 110: Headlight Bulb Removal
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. Headlight Bulb Removal 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer.
Page 111: Taillight/Brakelight Replacement
MAINTENANCE General Maintenance Taillight/Brakelight Replacement To replace a bulb on most EDGE models, remove the taillight lens screws and remove the lens to access the bulbs. On models with the adjustable seat bucket: 1. Remove the two sets of fasteners at the rear corners of the seat base.
Page 112: Clutch System
Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. 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. MAINTENANCE...
Page 113: Clutch Alignment Offset
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...
Page 114: Drive Belt Condition
MAINTENANCE General Maintenance n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist.
Page 115: Drive Belt Removal
MAINTENANCE General Maintenance Drive Belt Removal CAUTION 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 116: Drive Belt Installation
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 rota- tion by positioning the identification numbers so that you can read them.
Page 117: Drive Belt Deflection
MAINTENANCE General Maintenance 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 118: Torque Stop
General Maintenance Torque Stop If your snowmobile is equipped with an engine torque stop, periodi- cally check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010I-.030I (.25-.75mm) from the engine case. Adjust if necessary, and lock the jam nut.
Page 119: Tool Kit
Maintain the proper chain tension as outlined on page 102. 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...
Page 120: Track Inspection
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 snow- mobile off the ground.
Page 121: 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 mov- ing parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment is critical for proper handling.
Page 122 Track Maintenance Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 118. If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6.
Page 123: Track Alignment
MAINTENANCE Track Maintenance 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 124 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary. ✪ ✪ ✪ ✪ ✪ ✪ ✪...
Page 125: 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 126: Ski Skags
Steering System n 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 127: Rail Slide Wear
MAINTENANCE Steering System n Rail Slide Wear Measure slide thickness at several points along the rail. Have your dealer replace the slide when it's worn down to 7/16I (1.1 cm). Do not oper- ate the snowmobile if slide thickness measures less. Suspension Maintenance n Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause...
Page 128: 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 132 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 129: 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. Lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant.
Page 130: 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 131: 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 132: Battery Fluid
Battery Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks. WARNING 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.
Page 133: Battery Removal
MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When clean- ing is necessary, remove the corrosion with a stiff wire brush. Wash ter- minals 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 134: Battery Installation
Battery 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 nega- tive cable last to avoid the possibility of explosion. Battery electrolyte contains acid.
Page 135: Polaris Products
POLARIS PRODUCTS Part No. 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.) 2872347 Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.)
Page 136: 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 engagement...
Page 137 TROUBLESHOOTING 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 138 • 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 139 TROUBLESHOOTING 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 140 M-10 Suspension Troubleshooting Problem Solution Rear suspension bot- • Increase FRA position (see setup decal under hood for ini- toms too easily • Increase X-over tube length (see setup decal under hood) • Increase rear track shock coil spring preload •...
Page 141: 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 142: Warranty
Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information con- tained in this manual. Contact your Polaris dealer for replacement parts, ser- vice or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual.
Page 143 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 144: 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 145: 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 transpor- tation to and from the dealer is YOUR responsibility).
Page 146 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 147 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 148 • 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 149 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 150 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 151 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 152 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 153: 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 154 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
Page 155: Index
INDEX Accessories ....53 Air Pollution ....5 Airbox Warning .
Page 156 Park Brake Lever Lock ..60 POLARIS PRODUCTS ..132 Premium Fuel Switch ... 69 Pre-Ride Checklist .
Page 157 INDEX Snowmobile Engine Emissions Limited Warranty..148-149 Spark Plug Condition... 93 Spark Plug Removal ... 94 Spark Plugs .

This manual is also suitable for:

Edge 2006

Polaris 340 Edge Touring Owner's Manual

Table of Contents

Pre-Ride Inspections Pre-Ride Checklist

Quick Links

Chapters

Troubleshooting

Related Manuals for Polaris 340 Edge Touring

Summary of Contents for Polaris 340 Edge Touring

This manual is also suitable for:

Table of Contents