Polaris FS Classic Owner's Manual
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Polaris FS Classic Owner's Manual

Polaris FS Classic Owner's Manual

Polaris 2006 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. PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust, which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm, onto the snow on...
  • Page 4 S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...
  • Page 5 Industries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 6: Table Of Contents

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

  • Page 8: Introduction

    INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general representations.

  • Page 9: 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 10: Vehicle Identification Numbers

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

  • Page 11: Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.

  • Page 12: 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 13 SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. WARNING Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track.

  • Page 14: Riding Position

    Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; 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 15: Riding Apparel

    SAFETY Operator Safety Riding Apparel Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 22. WARNING Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury.

  • Page 16: Rider Capacity

    A decal on the console of these models indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only.

  • Page 17: Excessive Speed

    SAFETY Operator Safety Excessive Speed WARNING High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead.

  • Page 18: 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 19 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: S Take an avalanche class S Travel with experienced people S Travel on designated trails S Make sure each person is equipped with a shovel, probe and avalanche beacon.

  • Page 20: Driving Downhill

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

  • Page 21: Driving On Slippery Surfaces

    SAFETY Operator Safety Driving on Slippery Surfaces WARNING Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard-packed snow reduces steering and braking control, which may result in loss of control and serious injury or death.

  • Page 22: 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 23: Inadequate Snow Conditions

    SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile. Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine.

  • Page 24: Driving Responsibly

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

  • Page 25: Windchill/Temperature Charts

    SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART (°F) Wind Speed Calm Frostbite in >> WIND CHILL CHART (°C) Wind Speed Calm Frostbite in >> Actual Thermometer Reading (°F) Equivalent Temperature (°F) 30 min.

  • Page 26: Safety Decals And Locations

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

  • Page 27: Passenger Warning

    SAFETY Safety Decals and Locations “No Passenger” Warning Snowmobiles designed for a single rider only have a warning decal on the console below the steering post: Warming This vehicle is designed for operator only. “NO PASSENGER” Passenger Warning Snowmobiles designed for an operator and one passenger have a warning decal at the right side of the steering post.

  • Page 28: Reverse Warning

    Safety Decals and Locations Reverse Warning Reverse operation, even at low speeds, may cause loss of control resulting in serious injury or death. To avoid loss of control, always: Look behind before and while backing. Avoid sharp turns. Shift to or from reverse only when stopped. Apply throttle slowly.

  • Page 29: Operation Warning

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

  • Page 30: Features

    1. Front Bumper 2. Hood 3. Headlight 4. Passenger Lumbar Adjuster (Touring) 5. Windshield 6. Handlebar 7. Operator Seat 8. Passenger Seat (Touring) 9. Passenger Grab Handle 10. Grab Handle Heater Switch (Touring) 11. Trunk Cover or Storage Compartment 12. Taillights 13.

  • Page 31: Features

    FEATURES 1. Fuel Filler Cap 2. Rider Selectt 3. Ignition Switch 4. Handlebar hook 5. Brake Lever 6. MFD (Multi-Function Display) 7. Engine Stop Switch 8. Throttle Control 9. Hood Hold Down Straps 10. Parking Brake 11. Handlebar Grip Warmer Switch 12.

  • Page 32: Features

    Passenger Seat (Touring) The passenger seat features an adjustable lumbar support. To adjust for rider comfort, rotate the lumbar adjustment knob (A). Storage Compartments Trunk (Touring) Open the trunk cover (B) to access the rear storage compartment. The passenger seat and trunk cover are removeable to provide open storage for transporting larger items.

  • Page 33: Features

    FEATURES Radiator Compartment Access Panel The access panel ( ) is provided for cleaning debris from the radiator. Cargo Rack (Switchback) The maximum weight capacity for the cargo rack ( ) is 15 lbs. (7 kg). Always secure cargo before operating. Do not exceed the rack weight limit.

  • Page 34: Features

    WARNING If your snowmobile has five adjustment positions, do not remove the RIDER SELECT lockout. Your Polaris snowmobile has been engineered for this range of adjustability. Removing this lockout and using RIDER SELECT position 6 or 7 will result in the handlebars and brake lever contacting other components and interfering with steering and braking.

  • Page 35: Features

    FEATURES RIDER SELECT Adjustable Steering System Adjusting RIDER SELECT WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system.

  • Page 36: Features

    Engine Management System Malfunction Indicator Lamp (MIL) The MIL (Check Engine Indicator) will illuminate when the ECU detects a problem with engine management system components. If this occurs, see your dealer for service immediately. The MIL will blink in the event that the ECU detects an error with the turbo boost regulation system.

  • Page 37: Features

    FEATURES Engine Management System To protect the engine, the engine management system will limit engine RPM, vehicle speed or turbo boost (FST) if the following conditions are encountered. Vehicle Speed is Limited Cause Reverse is selected Defective rollover switch Throttle stuck, throttle lever depressed Throttle safety switch failure...

  • Page 38: Features

    Engine Management System Engine Overheats (FS) Indication At Vehicle Speed MPH (km/h) Flashing 0-31 (0-50) overheat lamp 32-46 (51-74) 47-62 (75-100) Above 62 (100) Flashing 0-31 (0-50) overheat lamp 32-46 (51-74) with with engine misfire 47-62 (75-100) Above 62 (100) Engine Overheats (FST) Indication At Vehicle...

  • Page 39: Features

    FEATURES Detonation Elimination Technology (DET) (Turbo Models) A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance. NOTE: Engine performance will be reduced if fuel with a lower octane than 91 is used.

  • Page 40: Features

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

  • Page 41: Features

    FEATURES Instrumentation MFD Settings MFD settings can be made with the engine running or with the engine off. If the engine is off, make sure the stop switch is pressed down and turn the ignition key to the START position briefly to activate the gauge.

  • Page 42: Features

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

  • Page 43: Features

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

  • Page 44: Features

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

  • Page 45: Features

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

  • Page 46: Features

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

  • Page 47: Features

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

  • Page 48: Gauge Cleaning

    Instrumentation MFD Battery Replacement 6. Install a new battery with fingers only. 7. Seal the end of the battery compartment using high strength double-sided tape between the two compartment halves or high strength single-sided tape around the outside of the compartment. 8.

  • Page 49: The Perfect Fit

    THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 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 50: Shock Damping

    Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris dealer for assistance before attempting to adjust preload. Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the rear suspension.

  • Page 51: Front Springs

    Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a Polaris dealer. Front Springs The front springs can be changed if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness.

  • Page 52: Rear Suspension Adjustments

    S In deep snow, a new rail slide will offer improved performance over a worn slide. It can also improve top speed. S Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated.
  • Page 53 THE PERFECT FIT Switchback Rear Suspension Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take this measurement with no rider and with the rear suspension at full extension.

  • Page 54: Limiter Strap Position

    Switchback Rear Suspension Rear Torsion Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information. A.
  • Page 55 THE PERFECT FIT Switchback Rear Suspension Rear Track Shock Compression Damping A. Turn rear track shock screw clockwise to stiffen compression. B. Turn the rear track shock knob clockwise for a softer ride. C. Turn the rear track shock knob counter clockwise for a stiffer ride.
  • Page 56 THE PERFECT FIT Switchback Rear Suspension Rear Shocks When adjusting, we recommend that you turn the adjuster slightly, then test ride. The recommended setting for this shock is eight (8) clicks counter-clockwise. FOX Zero Pro XC Shock The FOX Zero Pro XC shock is standard on the Switchback model. Turn the adjustment knob (L) on the shock reservoir to make adjustments to the compression damping.
  • Page 57 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 58 FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings 3. Subtract Y from X and you will have the SAG setting (X - Y = sag setting. Example: 21 - 17 = 4). The correct amount of SAG for the FAST M-10 rear suspension is 3-4 inches (8-10 cm).
  • Page 59 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 60 If FRA position alone does not allow the setup of the proper amount of sag, the center retainer of the rear track shock can be replaced with optional retainers to adjust the preload and change the sag. See your Polaris dealer for assistance. Retainer Insert Retainer Part...
  • Page 61 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height 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 62 FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings Ski Pressure 4. There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole (A) increases ski pressure while the upper hole (B) decreases ski pressure.

  • Page 63: Handlebar Adjustments

    THE PERFECT FIT Handlebar Adjustments Use the RIDER SELECT feature to adjust handlebar position. See page 31. Use the following steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover (A) to expose the handlebar and the four adjuster block bolts (B).
  • Page 64 3. Reinstall the knob assemblies and tighten securely. 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:...

  • Page 65: Traction Products

    Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products. See your dealer about installing studs and/or carbides. CAUTION Always install wear strips before installing studs.

  • Page 66: Carbide Skags

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

  • Page 67: Pre-Ride Inspections

    PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Drive Belt Condition Steering System Park Brake Lock/Brake Lever/Brake System...

  • Page 68: Throttle Lever

    Check 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 69: Hood Latches

    PRE-RIDE INSPECTIONS Check Before Starting the Engine Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed.

  • Page 70: Brake Lever Travel

    Check Before Starting the Engine 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 1/2″ (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.

  • Page 71: Park Brake Lever Lock

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

  • Page 72: Track Inspection

    Check Before Starting the Engine Track Inspection WARNING Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle. Use of traction products such as studs increases the possibility of track damage and/or failure.

  • Page 73: Suspension Inspection

    PRE-RIDE INSPECTIONS Check Before Starting the Engine Suspension Inspection Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip. Item Suspension mounting bolts Rear idler wheel bolts...

  • Page 74: Ignition Switch

    PRE-RIDE INSPECTIONS Check After Starting the Engine n Engine Stop Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. n Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF. n Lighting Check the headlight (high and low beam), taillight, and brake light.
  • Page 75 WARNING Operating a snowmobile with accident damage can result in serious injury or death. Do not operate the snowmobile if vehicle components have been damaged in a collision or tip-over. Have the snowmobile inspected by an authorized Polaris dealer.

  • Page 76: Operation

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

  • Page 77: Break-In Period

    OPERATION Break-In Period The break-in period for your new Polaris snowmobile is the first 500 miles (800 km) of operation. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

  • Page 78: Starting The Engine

    Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 65. Do not depress the throttle until the engine starts.

  • Page 79: Emergency Starting

    OPERATION Emergency Starting If the battery is too weak to start the engine, and a battery charger is not available, the engine can be started using jumper cables and a charged battery from another vehicle. Carefully read and follow the instructions below.
  • Page 80 16. If the engine still does not start, remove the jumper cables as outlined in step 17 and transport the snowmobile to an authorized Polaris dealer for service. 17. Carefully remove the jumper cables in this order: A. Remove the negative end of the jumper cable from the snowmobile chassis.

  • Page 81: Track Warm-Up

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

  • Page 82: Fuel Level

    Never use deicers or additives containing methanol. Polaris also recommends the use of Carbon Clean Plus. See page 133 for the part numbers of Polaris products. If you use oxygenated fuel containing ethanol, additional alcohol deicers or water absorbing additives should not be used.
  • Page 83 OPERATION n Engine Stop Switch Push down on the engine stop switch (L) to ground out the ignition and stop the engine quickly. Pull the switch up to the RUN position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.
  • Page 84 When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the snowmobile with the throttle safety switch disconnected. Return the snowmobile to an authorized Polaris dealer for service as soon as possible. Turbo Noise (FST)
  • Page 85 OPERATION Electronic Reverse (PERC 4t) Electronic reverse will activate only when the vehicle is stopped and engine speed is below 2500 RPM. Maximum engine speed when operating in reverse will be 6000 RPM. WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death.

  • Page 86: Emergency Stopping

    n Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 80 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Engine Stop Switch Throttle Safety Switch WHAT IT DOES Interrupts ignition circuit...

  • Page 87: Daily Storage

    OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4″ (10 cm) off the ground. Remove the key and cover the snowmobile.

  • Page 88: 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 control information (ECI) label and a factory-installed emissions information hangtag.

  • Page 89: Emission Control Information

    -related maintenance. The specified maintenance for the fuel filter is recommended additional emission- -related maintenance. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.

  • Page 90: Tool Kit

    Polaris dealer for service. NOTE: Polaris does not recommend tipping the snowmobile onto it’s side for service. Any time the snowmobile is tipped onto it’s left side, always check the oil level and clean the foam oil breather element.
  • Page 91 MAINTENANCE Periodic Maintenance Interval Table D = Perform Service = Replace " Item Engine Stop Switch Ignition Switch Throttle Safety Switch Taillight Brakelight Headlight 127 Inspect for wear or damage, replace Skags (Wear Bars) Fluid Leaks Parking Brake Brake Lever 106 Inspect level, add as needed Coolant 112 Inspect fluid level, add as needed...
  • Page 92 Periodic Maintenance Interval Table D = Perform = Replace " Item Coolant Hoses Heat Exchangers Throttle Lever 103 Inspect, replace if worn or damaged Fuel Lines Battery 124 Verify alignment, adjust as needed Track Alignment 122 Verify tension, adjust as needed Track Tension Handlebars 110 Verify tension, adjust as needed...
  • Page 93 MAINTENANCE Periodic Maintenance Interval Table D = Perform = Replace " Item Engine Mounts Spark Plugs 102 Inspect condition/gap, replace as Exhaust System 105 Check muffler and pipe condition, Hoses Brake Pads/Disc 103 Inspect, replace if worn or damaged Fuel Vent Lines Ski Toe 126 Verify alignment, see your dealer for Cooling Fins/...

  • Page 94: Engine Oil

    Polaris 4-cycle snowmobile engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. Oil may need to be changed more frequently if Polaris oil is not used. Always use 0W50 oil. Follow the manufacturer’s recommendations for ambient temperature operation.
  • Page 95 MAINTENANCE Engine Oil Oil Level Check NOTE: Read the entire oil check procedure before checking the oil level. The oil level will rise as engine temperature increases. The oil level will be lower when the engine is cold. To obtain a proper oil level reading, the snowmobile must be on a level surface, and the engine coolant temperature must be between 145 and 160 degrees F.
  • Page 96 Engine Oil Oil Level Check 6. Clean the dipstick with a clean shop towel and reinstall it, screwing it in completely. 7. Remove the dipstick and view the oil level. NOTE: The oil level reading will be accurate for only one to three minutes after turning off the engine.

  • Page 97: Oil Change

    Maintenance Table beginning on page 88. Clean the foam oil breather element with each engine oil change. See page 97. Always use the recommended oil. See page 91, or see your Polaris dealer about oil change kits, which contain a new filter and the recommended oil.
  • Page 98 Engine Oil Oil Change 9. Open the handlebar cover. Locate the connector with the BROWN and RED/WHITE wires. Connect the BROWN wire from the jumper harness to the BROWN wire on the handlebar harness by inserting the harness plug into the handlebar wiring harness connector.
  • Page 99 MAINTENANCE Engine Oil Oil Change 22. Make sure the engine coolant temperature is between 145 and 160 degrees F. (63-71 degrees C). If necessary, start the engine and allow it to idle until the coolant temperature is within the specified range.

  • Page 100: Foam Oil Breather Element

    Foam Oil Breather Element The foam oil breather element absorbs small amounts of liquid to protect sensors within the intake system from damage due to oil ingestion. Clean or replace the breather element at each engine oil change. Clean the element if the snowmobile has been tipped on its left side three times, either during service or while riding, as oil may leak into the element.

  • Page 101: Throttle Cable

    The front suspension and steering components do not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 88 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).
  • Page 102 MAINTENANCE Lubrication M-10 136 Rear Suspension Switchback Rear Suspension...

  • Page 103: Gearcase Oil

    Check and change the gearcase oil at the intervals outlined in the Periodic Maintenance Table beginning on page 88. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 133 for the part numbers of Polaris products. The dipstick (A) is located on the lower front side of the gearcase.
  • Page 104 Oil Change The drain plug (A) is located on the bottom of the gearcase. NOTE: Polaris does not recommend tipping the snowmobile onto it’s side for service. Any time the snowmobile is tipped onto it’s left side, always check the oil level and clean the foam oil breather element.

  • Page 105: Spark Plugs

    MAINTENANCE Spark Plugs A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. CAUTION Using non-recommended spark plugs can result in serious engine damage.

  • Page 106: Fuel Filter

    All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump. Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 88. Fuel Lines Inspect the fuel lines regularly for signs of deterioration or damage.

  • Page 107: Alternator Belt Inspection

    MAINTENANCE Alternator Belt Inspection Inspect the alternator belt condition and tension at the intervals outlined in the Periodic Maintenance Table beginning on page 88. 1. Stop the engine. 2. Open the hood. 3. Inspect the belt for wear, cracks or other damage. If the belt is worn or damaged, install a new belt.

  • Page 108: Exhaust System

    4. Replace any damaged or missing components. 5. Clean the plastic surfaces next to the muffler with aerosol Carburetor and Throttle Body Cleaner. NOTE: See page 133 for the part numbers of Polaris products. 6. Close the hood. MAINTENANCE...

  • Page 109: Cooling 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 133 for the part numbers of Polaris products. NOTE: Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.

  • Page 110: Flushing The Cooling System

    Have your Polaris dealer perform this service. Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Maintenance Table beginning on page 88.

  • Page 111: Bleeding The Cooling System

    MAINTENANCE Cooling System Bleeding the Cooling System WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas. 1. Read the entire coolant bleed procedure before beginning. After beginning the bleed procedure, do not stop the engine until reaching step 14.
  • Page 112 Cooling System Bleeding the Cooling System 8. With the engine idling, and while making sure that the level in the filler neck remains visible, observe the bleed return. If the system is self-bleeding properly, coolant will be pumped out of this hole. NOTE: Coolant flow may be erratic (spitting, misting) for the first few minutes of bleeding, but as long as the procedure is followed...

  • Page 113: Drive Chain Tension

    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 114: Hydraulic Brake Inspection

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

  • Page 115: Brake Fluid

    Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately. Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 133 for the part numbers of Polaris products.

  • Page 116: 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. 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 117: Removing Halogen Bulbs

    MAINTENANCE Lights Removing Halogen Bulbs 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. If fingers do touch the bulb, clean it with an alcohol-moistened towel.

  • Page 118: Electrical System

    Electrical System RELAY LABEL START SOLENOID RELAY CHASSIS CHASSIS RELAY RELAY RELAY RELAY IGNITION RELAY FUEL PUMP RELAY FAN RELAY FUSE LABEL Ground side of start solenoid SPARE None ACCESSORY Accessory plugs EMERGENCY SPARE 30A High beams Low beams CHASSIS CHASSIS Handwarmers Thumbwarmer...

  • Page 119: Clutch System

    CAUTION The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated. Do not lubricate clutch bushings. Clutch Alignment and Offset Clutch alignment offset (A) is important for maintaining optimum performance.

  • Page 120: Drive Belt Condition

    Clutch System 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. See Drive Belt Troubleshooting on page 140.

  • Page 121: Drive Belt Removal

    MAINTENANCE Clutch System Drive Belt Removal CAUTION Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. 1. Stop the engine after operating in a forward motion. NOTE: For easier accessibility, make sure the clutch tool access hole (...

  • Page 122: 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 rotation by positioning the identification numbers so that you can read them.

  • Page 123: Track Replacement

    MAINTENANCE Track Replacement When replacing the track, always install a track having the lug size recommended for your model. See your Polaris dealer. CAUTION Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel. Always install a track having the lug size recommended for your model.

  • Page 124: Track Lubrication

    Track Lubrication WARNING 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 periods on ice and other surfaces that have little or no snow for lubrication.

  • Page 125: Track Tension

    MAINTENANCE Track Tension WARNING Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track adjustment is critical for proper handling. Always maintain correct tension and alignment.
  • Page 126 Track Tension 4. Check for specified slack (C) between the wear surface of the track clip and the plastic rail slide. f the track needs adjustment: 5. Loosen the rear idler shaft bolt (D). 6. Loosen the locknuts (A). 10 lbs. (4.5 kg) 7.

  • Page 127: Track Alignment

    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 snowmobile with the track off the ground.

  • Page 128: 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 129: Ski Alignment

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

  • Page 130: Ski Skags

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

  • Page 131: Battery Removal

    MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.

  • Page 132: Battery Charging

    NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge. Battery...
  • Page 133 MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until thebattery voltage is 12.8 or greater.

  • Page 134: Battery Maintenance

    Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 133 for the part numbers of Polaris products. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts.

  • Page 135: Electrical Connections

    MAINTENANCE Extended Storage Engine Protection Fogging the engine is not recommended for this model. CAUTION Fogging the engine improperly can result in damage to the sensors. Fogging is not recommended. Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts.

  • Page 136: Polaris Products

    Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT4 Brake Fluid (12 oz.) 2872893 Engine Degreaser (12 oz.) 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carburetor and Throttle Body Cleaner POLARIS PRODUCTS...

  • Page 137: Troubleshooting

    TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Speed, RPM or Boost is Limited Possible Cause Engine Management System RPM Reduction Mode is activated Jammed clutch Jammed track Jammed or broken chaincase sprocket or chain Mechanical failure Engine Doesn’t Turn Over Possible Cause Low battery voltage Loose battery connections...
  • Page 138 Engine and Drive Train Troubleshooting Engine Turns Over, Fails to Start Possible Cause Out of fuel Water is present in fuel Old or non-recommended fuel Fouled or defective spark plugs No spark to spark plug Water or fuel in crankcase Clogged fuel filter Low battery voltage Poor engine compression...

  • Page 139: Engine Overheating

    TROUBLESHOOTING Engine and Drive Train Troubleshooting Engine Runs Irregularly, Stops or Loses Power Possible Cause Engine Management System RPM Reduction Mode is activated Low battery voltage Water is present in fuel Poor quality or low octane fuel Loose ignition connections Incorrect spark plug gap or heat range Fouled or defective spark plug Kinked or plugged fuel vent line...
  • Page 140 Engine and Drive Train Troubleshooting Harsh Drive Clutch Engagement Possible Cause Worn drive belt Excessive belt/sheave clearance Drive Belt Turns Over Possible Cause Incorrect belt Incorrect clutch alignment Broken or loose engine mount Drive System Noise Possible Cause Broken drive clutch components Bearing failure (chaincase, jackshaft or front drive shaft) Flat spots on drive belt surface...
  • Page 141 TROUBLESHOOTING Suspension Troubleshooting (Switchback) Problem Solution (perform only one change at a time) Rear suspension S Verify sag dimension (see page 50). Adjust torsion spring bottoms too easily S Increase shock compression damping (see page 53). Rear suspension S Check for binding suspension components and grease all rides too stiff S Verify sag dimension (see page 50).
  • Page 142 Suspension Troubleshooting (M-10) Problem Solution (perform only one change at a time) Rear suspension S Increase FRA position (see page 56). bottoms too easily S Install appropriate optional center retainer on rear track shock S Increase front track shock coil spring preload. S Revalve rear track shock compression damping (see your S Check track tension (see page 122).

  • Page 143: 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 en- gagement...

  • Page 144: Warranty

    2. Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. 3. Polaris warranty will aid in notifying the proper owner when a unit is recovered. 5. Details of trouble experienced 6.

  • Page 145: 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 146 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 147 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 148 S Failures caused due to improper adjustments. Failure due to unauthorized service. S Failures due to lack of service as required in the owner’s manual or Polaris updates. This includes off-season storage as listed in the owner’s manual. S Failure due to use of unauthorized parts or modifications.
  • Page 149 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 150 Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068 at the time of sale to the ultimate purchaser. Polaris warrants that the engine is free from defects in materials and workmanship that may keep it from meeting these regulations.
  • Page 151 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- -re- lated maintenance is not performed. Performance of other scheduled maintenance is strong- ly recommended, but is not necessary to keep the emissions- -related warranty valid.

  • Page 152: Maintenance Log

    Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) 150 mi. (240 km) 500 mi.

  • Page 153: Maintenance Log

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 154 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...

  • Page 155: Index

    INDEX Accessories ....Adjustable Headlights ... . Air Filter ..... Alternator Belt Inspection Avalanches .
  • Page 156 100-101 ..Passenger Passenger Grab Handle Adjustment Passenger Seat PERC Polaris Products Pre-Ride Checklist ..Pre-Ride Inspections ..Pressure Cap Radiator Compartment Access...
  • Page 157 INDEX Skags ......Ski Alignment ....Ski Pressure, M10 .

This manual is also suitable for:

Fst classicFs classic 2006Fst classic 2006Fs touring 2006Fst touring 2006Fst switchback 2006

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