Page 1 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth de- fects or other reproductive harm. 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 2 WARNING Adult Vehicle Only: This vehicle is designed for adult use only. The vehicle ¯ size, speed capabilities and control requirement prohibit operation by children. Operating With A Passenger: (On approved models only) Operating a vehicle ¯ with a passenger reduces your ability to control the vehicle due to the added weight and change in weight distribution.
Page 3 FOREWORD Thank you for purchasing a Polaris snowmobile. We believe it is the standard of excellence for all snowmobiles manufactured in the world today. Many years of experience in engineering, design, and development have gone into making your Polaris snowmobile the finest machine we have ever produced. All machines, no matter how well engineered, require a certain amount of mainte- nance.
Page 4 The Polaris Preferred Registered Owners (PRO) Family Your Owners Program As the owner of a new Polaris vehicle, you are entitled to a FREE two- year mem- bership in the Polaris PRO Family---the Preferred Registered Owners Family. It’s an owners program for Polaris owners like you, people who have chosen the finest recreational vehicle available, people who share an interest in Polaris and its prod- ucts.
Page 5: Table Of Contents
TABLE OF CONTENTS UNDERSTANDING WARNINGS ....... . SAFETY WARNING AND OPERATION DECALS .
Page 6: Understanding Warnings
UNDERSTANDING WARNINGS SAFETY ALERT The following precautionary signal words are used throughout this manual to con- vey the following messages: This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.
Page 7: Safety Warning And Operation Decals
SAFETY WARNING AND OPERATION DECALS WARNING Driving a snowmobile requires your full attention. Do not drink alcohol or use drugs or medications before or while driving as they will reduce your alertness and slow your reaction time. In most states and provinces it is prohibited by law to drive while in- toxicated or under the influence of drugs.
Page 8 SAFETY WARNING AND OPERATION DECALS WARNING Polaris Indys are high performance snowmobiles capable of traveling at very high speeds. Because of this, extra caution must be observed to ensure operator safe- ty. Particular caution must be taken to make sure that the snowmobile is in excel- lent operating condition at all times.
Page 9 SAFETY WARNING AND OPERATION DECALS Your snowmobile is not a toy. It is a well-engineered and well constructed recre- ational vehicle. The following information is provided to aid you in its safe opera- tion. NOTE: Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully.
Page 10 SAFETY WARNING AND OPERATION DECALS (Text Below) WARNING Read and understand warnings and the Owner’s Manual before operation. Severe injury or death can result from not heeding the warnings. Never consume alcohol or drugs before or while operating this vehicle. Night riding, limited visibility, or excessive speeds may cause over-driving of headlights resulting in insufficient time to react to terrain changes or avoid unexpected obstacles.
Page 11 SAFETY WARNING AND OPERATION DECALS (Text Below) 7075457 BEFORE STARTING ENGINE: Check throttle and brake for proper operation. Check to see that hood is securely latched. Check surroundings to verify clear op- eration area. Determine that steering is free and functional. BRAKE LEVER LOCK: May relax when used for long periods.
Page 12 SAFETY WARNING AND OPERATION DECALS WARNING AVERTISSEMENT Do not operate engine with hood open. N’opérez pas le moteur lorsque le capot est ouvert. Do not attempt adjustment with engine running. N’effectuez aucun ajustement lorsque le moteur est en marche. Do not operate engine with this guard open. Ne faites pas fonctionner le moteur lorsque ce garde de sécurité...
Page 13 SAFETY WARNING AND OPERATION DECALS Models Equipped With Reverse Only (Text Below) NOTE: Illustration of shift pattern may vary. Your model may differ. VEHICLE CAPABLE OF EXCESSIVE REVERSE SPEED! Reverse operation can be dangerous even at low speeds. Steering control becomes difficult in reverse.
Page 14: Safety Warning And Operation Decals
SAFETY WARNING AND OPERATION DECALS Some Liquid Cooled Models ATTENTION CAUTION Release pressure before removing cap. Cooling fluid must be up to the base of the pressure cap in hot or cold conditions. Refer to the Owner’s Manual for fluid level in overflow bottle. Do not operate above 40 mph with hood to air box foam removed or engine failure will result.
Page 15: Operation Warnings
OPERATION WARNINGS Before Starting The Engine Read and Understand Your Owner’s Manual Read the Owner’s Manual completely now, and re-read it occasionally. We have attempted to provide you with as much information as possible to alert you to the safety requirements of snowmobiling. Check Throttle and Brake for Proper Operation The throttle and brake are the primary controls of your snowmobile.
Page 16 OPERATION WARNINGS Driving 2-Up When operating a 2-Up machine with a passenger, the driver should be aware that more space will be required to make turns, and a longer distance will be necessary for stopping. Lower speeds should be observed whenever riding 2-Up. CAUTION: Always make certain the passenger remains seated behind the driver, facing forward, with both feet placed firmly on the running boards.
Page 17 OPERATION WARNINGS Stay Clear of Track During warm-up and operation, stand clear of the rotating track. Do not use too much throttle during warm-up or when track is free hanging. Entanglement and serious injury or death may result. Do Not Operate Engine With Clutch Guard Removed The clutch guard is designed to protect the operator from metal parts in the event the clutch should fail.
Page 18: Hydraulic Brakes
OPERATION WARNINGS Hydraulic Brakes The need for a properly functioning brake is vital. Polaris snowmobiles are equipped with the highest quality hydraulic disc brake system available. The fol- lowing items must be checked each time before starting the engine to assure prop- er operation.
Page 19: Park Brake Lever Lock
OPERATION WARNINGS Park Brake Lever Lock Brake Handle Park Brake Lever Lock (Not all models are equipped with a park brake) Master Cylinder Reservoir Master Cylinder Cover Fluid Level Indicator Your snowmobile has a brake brake lever lock. It is located over the brake lever.
Page 20 OPERATION WARNINGS Auxiliary Shut-Off Switch Check auxiliary shut-off switch for proper operation. Push down to stop engine. Pull up to release and start engine. Tether Switch (accessory on all models) Check tether switch for proper operation. Remove Ignition Key Don’t tempt anyone to steal or ride your snowmobile without permission by leaving the key in the ignition.
Page 21 OPERATION WARNINGS Stop Engine Before Attempting Adjustments WARNING The snowmobile engine compartment contains moving parts. Shields and guards have been provided for your safety, but it is still possible to carelessly get your hands or fingers into a moving belt or a rotating shaft. For this reason never attempt adjustments with the engine running.
Page 22 OPERATION WARNINGS D Wire fences are a serious hazard. Unless you are thor- oughly familiar with an area, you should always be on the alert for fences. Single strands are especially dan- gerous, since there can be a great distance between posts.
Page 23 OPERATION WARNINGS D Remember, the sound of your ma- chine will drown out the sound of approaching vehicles. Look ahead, behind, and to the sides before turn- ing or crossing railroad crossings or highways. Steep embankments may also hide your view. Always leave yourself a way out.
Page 24 OPERATION WARNINGS Windchill/Temperature Charts The following information is provided as a guide to determine what temperatures are dangerous when riding your snowmobile. WIND CHILL CHART (°F) Estimated Actual Thermometer Reading (°F) Wind Speed in Wind Speed in Equivalent Temperature (°F) Calm --57 -112...
Page 25: Cold Weather Driveaway
OPERATION WARNINGS Cold Weather Driveaway Whenever the machine has been parked for some length of time, especially over- night, always shake loose the skis and track before attempting to put the machine into motion. The throttle should always be opened with enough authority to put the machine into motion, staying within safety limits and with respect to a passenger, on a two passenger machine.
Page 26 OPERATION WARNINGS Hard Packed Snow WARNING Steering and braking control are substantially reduced under packed snow or icy conditions. Excessive shifting of operator body weight when turning on hard packed snow or slippery surfaces can result in loss of vehicle control and serious injury. Reduce speed as required to maintain control under these conditions.
Page 27 OPERATION WARNINGS Hilly Terrain Exercise caution and good judgement when travelling in hilly terrain. Crossing a Slope (Sidehilling) WARNING Sidehilling can be very dangerous and is not recommended for inexperienced snowmobilers. Crossing the face of a slope (sidehilling) requires the operator to position his/her weight in order to maintain proper balance.
Page 28: Riding Uphill
OPERATION WARNINGS Riding Uphill Hill climbing may be accomplished by using one of two methods, depending upon the steepness of the hill. Sidehilling may be used if there are few obstacles on the hill. The operator should assume a kneeling position (as in Sidehilling), keeping body weight on the uphill side at all times.
Page 29 OPERATION WARNINGS Responsible Driving If you operate the snowmobile improperly, you will cause situations which will ex- ceed your driving skills. Each snowmobile handles differently, and even if you are a seasoned driver, it is strongly recommended that you spend some time getting the feel for this particular machine before attempting ambitious maneuvers.
Page 30: Preservation Of The Environment
PRESERVATION OF THE ENVIRONMENT We recommend that you drive your snowmobile with consideration for the protec- tion and preservation of our environment. Noise Level Probably the most publicized subject with regard to snowmobiles is noise. The So- ciety of Automotive Engineers (SAE), which is the standard-setting body for snow- mobiles, has recommended that snowmobiles conform to prescribed sound levels.
Page 31: Identification And Specifications
IDENTIFICATION AND SPECIFICATIONS Vehicle Nomenclature Refer to illustrations on following pages. NOTE: Illustrations are a general repre- sentation. Your model may differ. Hood Suspension Headlight Nosepan Windshield Trailing Arm Handlebar Skis Seat Front Bumper Storage/Rear Console Taillights Vehicle I.D. Number (Right Side) Backrest Rear Bumper Tunnel Extension...
Page 32 IDENTIFICATION AND SPECIFICATIONS Vehicle Nomenclature, Cont.
Page 33 IDENTIFICATION AND SPECIFICATIONS Vehicle Nomenclature, Cont.
Page 34 IDENTIFICATION AND SPECIFICATIONS Controls and Instruments General Representations Your Model May Differ Headlight Dimmer Switch (2 Position) Fuel Filler Cap/Gas Gauge Auxiliary Shut-Off Switch (Push/Pull). Operation found on page 40. Throttle Control Recoil Starter Handle Choke Control Ignition Switch 8. Tachometer (may include indicator / warning lights) Speedometer (may include indi- cator / warning lights)
Page 35 IDENTIFICATION AND SPECIFICATIONS Backrest 1. Backrest Cushion Adjuster 2. Backrest Adjuster Cable 3. Grab Bar Adjustment Knob 4. Passenger Handwarmer Switch 5. Wind Deflector 6. Backrest Adjustment Lever 7. Passenger Hand Hold...
Page 36: Operation
OPERATION Carburetion Proper carburetor adjustment is critical, since a mixture too lean (too much air, too little fuel) will result in overheating of the combustion chamber causing pre-ignition of the fuel. This results in piston burning, bearing failure, or complete engine fail- ure.
Page 37: Oil Injection System
OPERATION Lubrication The fuel and oil which enter the engine through the fuel and oil injection systems provide the only source of engine lubrication, and must be of the highest quality. You can understand the importance of proper lubrication when you realize that at 6000 RPM the crankshaft is rotating 100 revolutions per second.
Page 38 OPERATION WARNING Never mix brands of two cycle oil. Serious chemical reactions can occur, causing injection system blockage resulting in severe engine damage and voiding of en- gine warranty. CAUTION: Always maintain the oil level in the oil tank above the low level line. The low oil indi- cator light will indicate when to add oil.
Page 39 OPERATION Fuel WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where re- fueling is performed or where gasoline is stored.
Page 40: Premium Fuel Switch
OPERATION Fuel The fuel used in the Polaris engine is as important to engine life and performance as the lubricant used. Most Polaris engines are designed to run on 87 octane non oxygenated or 89 oc- tane oxygenated pump gasoline. There is a great deal of variability in the quality of the 87 octane gasoline available across the country.
Page 41: Fuel Reserve Capacity
OPERATION Fuel Reserve Capacity On equipped models, when the fuel gauge reads “RES”, there are approximately 2 gallons of fuel left in the tank. Fuel System Deicers If you are using non-oxygenated fuel, Polaris recommends the regular use of Iso- propyl base fuel system deicer (Polaris PN 2870505).
Page 42 OPERATION Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in for a new or rebuilt engine. Familiarize yourself and others with the following procedure for your Polaris snowmobile. Premix the first tank of gasoline with one pint of Polaris injection oil for each 5 gal- lons of fuel.
Page 43 OPERATION Pre-Starting WARNING Before starting the engine, always refer to all safety warnings pertaining to snow- mobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Operation Warnings beginning on page 10. Important safety items include, but are not limited to: D Throttle system D Brake system D Steering system...
Page 44 OPERATION Starting a Warm Engine Turn key to “On”. Pull kill switch (shut-off switch) up to “run” position. Grasp starter handle and pull slowly until recoil engages; then pull to start. If the engine does not start on the first pull, slightly depress the throttle with your left hand (no more than 1/4″...
Page 45 OPERATION Auxiliary Engine Shut-Off Switch To stop the engine in an emer- gency, push down on the auxilia- ry shut-off switch (A). This will ground out the ignition and bring the engine to a quick stop. To re- start the engine the switch must be pulled up to the “On”...
Page 46 OPERATION WARNING If the throttle lever does not work properly, do not start the engine. If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures. If the engine does not start, take the snowmobile to an authorized Polaris dealer for service.
Page 47 OPERATION Emergency Stopping Procedures The following chart lists methods for stopping the engine in the event of an emer- gency. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit Brake Slows drive shaft Choke Floods engine 1/2 throttle or less Auxiliary Shut-Off Switch Interrupts ignition circuit Throttle Safety Switch Interrupts ignition circuit...
Page 48 OPERATION Pre-ride Warm Up The following steps must be taken to ensure proper warm up of the engine, drive train and track. With the snowmobile securely supported by the rear bumper, and approximately 4″ (10 cm) off the ground, use the follow- ing procedure.
Page 49: Operation
OPERATION Towing WARNING For your safety, the proper function of a tow hitch must be understood before at- tempting its use. Do not tow toboggans, sleds, saucers, or any type of vehicle with a rope. No brak- ing power can be applied to an object being towed with a rope. Only a stiff metal pole connecting the towed object and tow hitch on the snowmo- bile should be used.
Page 50: Battery
BATTERY Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept be- tween the upper (1) and lower (2) level marks. To refill use only dis- tilled water. Tap water contains minerals which are harmful to a battery.
Page 51: Battery Removal
BATTERY Battery Removal CAUTION: Whenever removing or reinstalling the battery, disconnect the negative (black) cable first and reinstall the negative cable last to avoid the possibility of explosion. Disconnect hold down straps holding battery in position. Remove battery vent tube from battery. Disconnect black (negative) battery cable first.
Page 52 BATTERY Battery Installation WARNING To avoid the possibility of explosion, always connect battery cables in the order specified. Red (positive) cable first, black (negative) cable last. Set the battery in its holder. Attach the hold down strap. Install the battery vent line. It must be free from obstructions and securely installed.
Page 53: Maintenance
MAINTENANCE Polaris Recommended Owner Maintenance Program Your Polaris snowmobile has been engineered and manufactured by skilled Polar- is personnel to the highest degree of performance and reliability possible. In order to maintain this high degree of performance and reliability your Polaris must be giv- en regular service and maintenance inspections.
Page 54 MAINTENANCE Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are ex- plained on the following chart and maintenance pages of this manual. For continued maximum machine performance and component life, it is recom- mended that maintenance checks be performed at 1000 mile (1600 km) intervals.
Page 55 MAINTENANCE ITEM WEEKLY 150MI. 1000 MI. 2000 MI. (240 KM) (1600 KM) (3200 KM) PAGE BEFORE LONG TRIP Inspect coolant filter and re- place Grease ski pivots Grease center steering arm(s) Lubricate steering post sup- port bracket and pivot (aero- sol) Check cylinder base stud torque on all 600 and 700 Po-...
Page 56 MAINTENANCE 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 mainte- nance and services performed on the unit. 150 Mile (240 km) Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date...
Page 57 MAINTENANCE Adjustments It is your responsibility as the snowmobile owner to perform preventative mainte- nance and periodic adjustments. Many of the items listed in this section you can perform yourself. However, at times your snowmobile may need service requiring special tools and technical skills. In these situations, we recommend you contact your Polaris dealer.
Page 58 MAINTENANCE Coupler Greasing - WideTrak Grease couplers on driveshaft and jackshaft NOTE: Grease points in the illustrations are indicated by a Jackshaft Driveshaft Transmission Jackshaft Bearing Greasing Loosen driven clutch retaining bolt and pull clutch outward to expose bearing and grease fitting.
Page 59: Intake Filter
MAINTENANCE Intake Filter The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check top of foam filter periodically to remove any accu- mulation of snow. Do not operate machine with the intake filters removed. This CAUTION: can cause carburetor icing resulting in poor fuel economy or carburetor malfunction.
Page 60 MAINTENANCE Under Hood Air Intake System The Indy 340s are equipped with an under hood air intake system which should normally be left open. The door should be closed and latched above 35° F (2° C) for maximum perfor- mance during warm weather operation.
Page 61: Spark Plug Selection
MAINTENANCE Spark Plug Selection Original equipment parts or their equivalent should always be used. However, the heat range of spark plugs is of utmost importance. A spark plug with a heat range which is too high will cause engine damage. A spark plug with a heat range which is too low will cause excessive fouling and malfunction.
Page 62 MAINTENANCE Spark Plug Removal and Replacement WARNING Never attempt to remove the spark plug while the engine is warm. The exhaust system or en- gine could burn you, causing severe injury. The spark plug is removed by using the special wrench (1) provided in the tool kit.
Page 63 MAINTENANCE Water Pump Belt Inspection Some liquid cooled models will Replace if width is less require an inspection of the wa- terpump belt. This belt inspec- than .25″ (6.35mm). tion interval is 1500 miles (2400 Nominal new width is km). Inspect belt width and con- .345″...
Page 64 MAINTENANCE Water/Sediment Trap Service Most Polaris snowmobiles incorporate patented carburetor bowl water/sediment traps which are located at the bottom of each carburetor. The trap consists of a hose with a plug, which should be inspected for contamination and drained at least every 2000 miles (3200 km).
Page 65 MAINTENANCE Fuel Filter/Fuel Lines CAUTION: The fuel filter (3 - external fuel filter) (4 - in-tank fuel filter) and fuel lines should be inspected regularly. Special attention should be given to the system’s fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds can occur.
Page 66: Carburetor Adjustments
MAINTENANCE General Carburetor Information The number size stamped in the end of the main jet indicates the jet size which was installed at the time of manufacture. The installed main jet is not necessarily correct for your elevation. It is the Polaris dealer’s responsibility to ensure that the correct main jets are installed in each machine for your area of operation.
Page 67 MAINTENANCE ACCS Air Box Vent Line Attachment ACCS Valve Some models are equipped with the Polaris ACCS (Altitude Compensating Carbu- retor System). The ACCS is designed to compensate automatically for changes in altitude without having to change carburetor jets. See your dealer for ACCS ser- vice or adjustment.
Page 68: Exhaust System
MAINTENANCE Carburetor Protection During Off Season Storage Whenever the machine is stored for a period of more than 60 days it is highly rec- ommended that the engine be fogged with Polaris PN 2870791. Follow the engine fogging instructions provided on the can. See pages 85-86 for more complete in- formation about storing your machine during the off season.
Page 69: Coolant Level
MAINTENANCE Engine Cooling - Liquid Cooled Models The cooling system on the liquid cooled Indy consists of the following major com- ponents: recovery tank, water pump, cylinders, heads, inlet and outlet manifolds, pressure cap and heat exchangers. The heat exchangers are located beneath the running boards and front close-off panel in front of the drive shaft and/or under the seat.
Page 70: Bleeding The Cooling System
MAINTENANCE Bleeding the Cooling System WARNING Never bleed the cooling system when the engine is hot. Severe personal injury could result from steam or hot liquid. Never remove the pressure cap (1) when the en- gine is warm or hot. If the pressure cap is to be re- moved, the engine must be cool.
Page 71: Throttle Cable Lubrication
MAINTENANCE Surge Tank Models Remove the pressure cap from the recovery tank and fill with properly mixed coolant to the maximum indicated mark. Elevate front end of machine slightly to aid bleeding of the heat exchangers. Remove the bleed screw from the water outlet manifold and/or the thermostat housing.
Page 72 MAINTENANCE Chaincase Oil Level The drive chain is continuously immersed in oil. Proper oil level is determined by checking the level on the dipstick (C) with machine placed on a level surface. The oil level should be between the “safe” marks on the dipstick. Add oil through dip- stick opening to maintain proper level.
Page 73 MAINTENANCE Gearcase Oil Level (WideTrak Models) Using Polaris Chaincase Oil (PN 2871281), maintain the proper oil lev- el. Proper oil level is determined by checking the level on the dipstick (A) with machine placed on a level sur- face. The oil level should be between the “safe”...
Page 74: Brake Inspection
MAINTENANCE Brake Inspection The brake lever reserve should be inspected frequently. Mea- sure the clearance between the lever and handlebar grip. In- spection should be made with the lever firmly depressed. Le- ver reserve (A) should be no less than 1/2″ (1.3 cm). Replacement of brake pads will be necessary when the brake pad material is thinner than the...
Page 75 MAINTENANCE Replenishing Brake Fluid CAUTION: Brake fluid is a hazardous material. Contact with decals, paint, and many plastics will cause damage. Use proper precautions when handling brake fluid. Remove brake fluid master cylinder reservoir cover. Add Polaris brake fluid (PN 2870990) as required to bring the level up to the top of the fluid level mark on the inside of the reservoir.
Page 76: Bleeding The Hydraulic Brake System
MAINTENANCE Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause a springy or spongy brake lever action. Bleeding is necessary to remove air from the system. Refer to illustration on page Remove brake fluid master cylinder reservoir cover and gasket. CAUTION: Brake fluid is a hazardous material.
Page 77 MAINTENANCE Brake Adjustment - Mechanical Brakes If excessive brake lever to brake block clearance is evident, the brake cable or cali- per should be adjusted using the following methods. When adjusting calipers, ad- just caliper adjuster bolt only. Do not adjust cable or cable sleeve length. WARNING Improper brake adjustment could result in brake failure which could result in severe injury or death.
Page 78 MAINTENANCE Cable Adjustment (Cont.) Slip long leg of lever spring (D) off caliper and rotate to the side. Rotate lever (E) one tooth in the direction opposite the actuation direction and tighten bolt. Make sure spline teeth are properly engaged. Bend up a tab (C) aligning with one of the bolt head flats to prevent bolt rotation.
Page 79 MAINTENANCE Brake Inspection WARNING Be certain brake pads do not drag on disc and brake lever travel is not excessive. Replacement of brake pads will be necessary when the brake pad material is thin- ner than the backing plate approximately (1/16″). A kit is available for replacing brake pads.
Page 80: Headlight Adjustment
MAINTENANCE Headlight Adjustment The headlight can be adjusted for vertical 25’ (7.6 m) aim using the following procedure: Place snowmobile on a level surface with headlight approximately 25’ (7.6m) from a wall. Lamp Center Measure distance from floor to Height center of headlight and make a mark on the wall.
Page 81 MAINTENANCE NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a resi- due, causing a hot spot which will shorten the life of the lamp. Removing Halogen Bulbs - Low Beam Pinch ends of the spring (1) together and lift until it releases from the spring retainer.
Page 82 MAINTENANCE NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a resi- due, causing a hot spot which will shorten the life of the lamp. Removing the Side Bulbs Disconnect terminal from back of bulb. Turn bulb assembly 1/4 turn to right and withdraw from housing.
Page 83 MAINTENANCE Handlebar Adjustment - All Other Models Your snowmobile has handlebars which may be adjusted for your person- al fit. Remove handlebar cover and foam. Using a 7/16″ (11 mm) wrench, loosen four nuts on bottom of adjuster block. NOTE: Turn handlebar to left or right for access to back nuts.
Page 84: Backrest Adjustment
MAINTENANCE Backrest Adjustment The passenger backrest on some models is adjustable. To move the backrest for- ward or backward, lift the adjustment lever on the left side (A). To lengthen or shorten the backrest cable, lift the cable until spring tension is felt and lock the jamb nut.
Page 85 MAINTENANCE Drive Belt WARNING Periodically check the condition and tension of the drive belt. Always carry a spare belt. Inspect clutch sheaves for damage, wear, or belt residue. Clean with non-oil base cleaner such as isopropyl alcohol. To ensure satisfactory belt life, install belts so they operate in the same direction of rotation.
Page 86: Clutch System
MAINTENANCE Clutch System Do not lubricate clutch bushings. The bushings in the weights and rollers of Polaris clutches are made of a material which may be damaged if lubricated. Clean clutch sheaves periodically to maintain optimum performance. WARNING All clutch maintenance and repairs must be performed by an authorized Polaris servicing dealer.
Page 87 MAINTENANCE Clutch Center Distance Straight Edge Measure at Measure belt deflection with both this point clutches at rest and in their full neutral position. Place a straight edge on the belt and apply downward pressure while mea- suring at the point shown. The recommended center distance for your machine can be found on the Owner’s Manual Specification Sup-...
Page 88: Torque Stop
MAINTENANCE Torque Stop If your machine is equipped with a torque stop, periodically check torque stop clearance. Before this procedure it will be necessary to ensure the clutches are properly aligned. The torque stop clearance should be a minimum of .010″ to a maximum of .030″...
Page 89: Reverse Operation
MAINTENANCE Reverse Operation WARNING This snowmobile is capable of excessive reverse speed! Reverse operation can be dangerous even at moderate speeds. Steering control becomes difficult in re- verse. Misuse of reverse can result in serious injury or death. The transmission may not always be in the gear indicated by the shift lever. Apply the throttle slowly until the correct gear is assured.
Page 90: Electrical Connections
MAINTENANCE Extended Storage Off season or extended storage of your snowmobile requires you to take preventa- tive measures to aid against deterioration and to prolong the useful life of many components. Cleaning and Preservation of Hood, Chassis, and Trim Proper storage starts by cleaning, washing, and waxing the hood, chassis, uphol- stery, and plastic parts.
Page 91: Track And Suspension
MAINTENANCE Engine and Carburetor Proper off season preparation of the engine and fuel system is vital to the preven- tion of rust and corrosion formation on precision engine parts during storage. Without proper storage, jet restriction can cause lean conditions and very poor slow speed driving quality.
Page 92 MAINTENANCE Transporting the Snowmobile Whenever the snowmobile is transported the following measures should be taken: Turn the fuel valve to “Off”. Be certain the fuel cap and oil cap are installed correctly. Always tie the snowmobile to the transporting unit securely using suitable straps.
Page 93: Tool Kit
MAINTENANCE Fall Tune Up To obtain maximum performance and use from your snowmobile, we encourage you to arrange for a fall service tune-up with your Polaris dealer. He has an experi- enced and trained service technician who is interested in keeping your machine in peak operating condition.
Page 94: Track Tension Data
MAINTENANCE Track Tension Data Suspension Weight Measurement Measurement (Refer to Specifi- Location cation Supple- ment for type) XTRA 12 121″ none 2″ behind rail 1/2″ (1.27 cm) bumper free hanging XTRA 12 133″ none 16″ ahead of rear 1-1 1/8″ (2.54 - idler shaft 2.86 cm) free hanging...
Page 95: Track Tension
MAINTENANCE Track Tension Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Tension adjustments should be XTRA 10 made only after the track is Hi-fax warmed up and limber. Turn the machine off. Lift the rear of the machine and safely support it off the ground.
Page 96 MAINTENANCE XTRA LITE Hi-fax Track 10 lb. Weight XTRA 12 (4.5 kg) 2″ Rear Track idler adjusting shaft bolt bolt Rail bumper 121″ = 1/2″ Track 133″ = 1-1 1/8″ measured 16″ahead Hi-fax of rear idler center...
Page 97: Track Alignment
MAINTENANCE WARNING When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury. Track Alignment A periodic check should be made to see that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail.
Page 98 MAINTENANCE Track Warm Up When storing your snowmobile outside overnight, it is recom- mended that the track be warmed up prior to driving the snowmo- bile. This reduces belt and drive clutch wear. To warm up the track, safely support the rear of the snowmobile off the ground, start the engine and abruptly en- gage the clutch.
Page 99 MAINTENANCE Track Inspection WARNING Never make this maintenance check with the engine running, as serious personal injury can result. Using a hoist, safely lift and sup- port the rear of the snowmobile off the ground. Rotate the track by hand to check for any possible damage.
Page 100: Track Lubrication
MAINTENANCE Track Lubrication WARNING Track failure, loss of vehicle control and braking ability can result from extended use of this vehicle on surfaces providing marginal lubrication between hi-fax and track guide clips. Examples of marginal lubrication would include lakes without snow cover, icy trails and no-snow conditions.
Page 101 MAINTENANCE WARNING Proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard packed snow or ice. Loss of control can result in severe personal injury or death. If your machine is equipped with carbide skags or you are adding them, it may also be necessary to add track studs in order to maintain proper vehicle control while turning on hard packed snow or ice.
Page 102 MAINTENANCE Wear Strips Most models come from the fac- tory with tunnel wear strips or wear strip coolers installed. Check your specification sup- plement to see if your model has Wear strip wearstrips. These wear strips mounting are designed for a specific stud holes length.
Page 103 MAINTENANCE Steering System The steering systems on Polaris snowmobiles have the following adjustments: D Ski toe or alignment D Handlebar centering D Spindle camber Improper adjustment of these components can cause erratic steering. Consult your dealer if a need for adjustment should become necessary. Steering Inspection and Adjustment The steering assembly of the machine should be checked pe-...
Page 104 MAINTENANCE 10″ 10″ CRC Suspension with Rack Steering 10″ 10″ All other steering systems...
Page 105: Ski Skags
MAINTENANCE Ski Skags Steel Ski The skag is a replaceable bar attached to the underside of the ski. The purpose of the skag is to assist in turning the snowmo- bile and to prevent the wearing Standard Skag away of the ski caused by con- tact with roads and other bare terrain.
Page 106: Suspension Maintenance
MAINTENANCE Hi-Fax Wear Hi-fax wear patterns are some- what different on XTRA™-12 suspension models. The rear portion will wear rapidly at first. After this initial break in period the rapid wear will cease. Re- placement is not necessary un- til a thickness of 5/16″ (.8 cm) is reached.
Page 107 MAINTENANCE CAUTION: If suspension bolts are re- moved, the threaded shaft must be cleaned thoroughly with a brake parts type cleaner. A new bolt, which must have a locking patch on the threads, must be installed. See your dealer for the correct fastener for this ap- plication.
Page 108: Suspension Lubrication
MAINTENANCE Suspension Lubrication To maintain rider comfort and to retard wear of the pivot shafts, the suspension piv- ot shafts should be lubricated with Polaris Premium All Season Grease, PN 2871066, at 500 miles (800 km) initially; 1000 miles (1600 km) and before summer storage each year.
Page 109 MAINTENANCE Suspension Lubrication NOTE: The following illustrations are general representations. Your model may differ. Lubrication points are indicated by a L and forward is to the left. Forward Forward...
Page 110: Maintenance
MAINTENANCE Suspension Lubrication NOTE: The following illustrations are general representations. Your model may differ. Lubrication points are indicated by a L and forward is to the left. (Both sides) Forward...
Page 111: Suspension
SUSPENSION Independent Front Suspension (IFS) Components Refer to illustrations on following pages. NOTE: Illustrations are a general repre- sentation. Your model may differ. IFS Compression Spring IFS Shock Absorber Trailing Arm Ski Spindle Ski Pivot Ski Stop Ski Pivot Bushing Lower Radius Rod Upper Radius Rod...
Page 112 SUSPENSION Independent Front Suspension (IFS) Components...
Page 113 SUSPENSION IFS Adjustment and Ski Pressure Increasing spring preload will increase ski to ground pres- sure. Decreasing spring pre- load will decrease ski to ground pressure under all throttle posi- tions. NOTE: Increasing the IFS spring preload too far can adversely affect the handling of the snowmobile and rear sus- pension performance.
Page 114 SUSPENSION IFS Adjustment Shock Absorber Components Retainer Shock Rod Jounce Bumper Body When adjusting, be sure springs on both the left and right sides of the machine are at the same adjust- ment. For the best ride the spring preload should be as low ;as possible.
Page 115 SUSPENSION “Indy Select” IFS Shock Some snowmobiles are equipped with “Indy Select” IFS shocks, which allow the driver to make adjustments to the compression valving of the front shocks by turn- ing adjustment screws (A) located near the base of the shocks. By turning the screw clockwise, the compression of the shock increases, stiffening the ride.
Page 116 SUSPENSION - XTRA 10 Refer to illustrations on following pages. NOTE: Illustrations are a general repre- sentation. Your model may differ. Compression Valving Adjustment Screw Rear Limiter Strap RRSS (Rear Rear Scissor Stop) FRSS (Front Rear Scissor Stop) Limiter Strap (Adjustable) Limiter Strap (Quick Adjust) Rear Torsion Spring Adjuster(Cam - Low Position Shown) Front Limiter Strap...
Page 117 SUSPENSION Rear Suspension Components - Xtra-10 Type NOTE: General representation only. Your model may differ.
Page 118 SUSPENSION Rear Suspension Components - Xtra-10 Type Forward...
Page 119: Suspension Adjustment
SUSPENSION Suspension Adjustment The XTRA™ 10 suspension has been designed and set up to deliver a soft ride un- der average riding conditions. Rider weight, riding styles, trail conditions, and ve- hicle speed each affect suspension action. The suspension can be adjusted to suit rider preference and deliver excellent per- formance for a given set of conditions.
Page 120 SUSPENSION - XTRA 12 Refer to illustrations on following pages. NOTE: Illustrations are a general repre- sentation. Your model may differ. Compression Valving Adjustment Screw RRSS (Rear Rear Scissor Stop) FRSS (Front Rear Scissor Stop) Limiter Strap (Adjustable) Rear Torsion Spring Adjuster(Cam - Low Position Shown) Front Track Shock Torsion Spring Rear Track Shock...
Page 121 SUSPENSION Rear Suspension Components - Xtra-12 Type...
Page 122 SUSPENSION Rear Suspension Components - Xtra-12 Type Forward *NOTE: General representation. Your model may differ.
Page 123 SUSPENSION Suspension Adjustment The XTRA™ 12 suspension has been designed and set up to deliver a soft ride un- der average riding conditions. Rider weight, riding styles, trail conditions, and ve- hicle speed each affect suspension action. The suspension can be adjusted to suit rider preference and deliver excellent per- formance for a given set of conditions.
Page 124 SUSPENSION Rear Suspension Components - Xtra Lite Type Refer to illustrations on following pages. NOTE: Illustrations are a general repre- sentation. Your model may differ. Front Track Shock Torsion Spring Rear Track Shock Carrier Wheel Rail Tip Hi-fax Slide Rail Bogie Wheel Rail Bumper 10.
Page 125 SUSPENSION Rear Suspension Components - Xtra Lite Type NOTE: General representation only. Your model may differ. Forward...
Page 126 SUSPENSION Rear Suspension Components - Wide Trak/Tran Sport Refer to illustrations on following pages. NOTE: Illustrations are a general repre- sentation. Your model may differ. Front Track Shock Torsion Spring Rear Track Spring Carrier Wheel Rail Tip Hi-fax Slide Rail Bogie Wheel Rail Bumper 10.
Page 127 SUSPENSION Rear Suspension Components - Wide Trak Forward...
Page 128 SUSPENSION Suspension Adjustment The Polaris WideTrak and Xtra Lite Type Suspensions have been designed and set up to deliver a soft ride under average riding conditions. Rider weight, riding styles, trail conditions, and vehicle speed each affect suspension action. The suspension can be adjusted to suit rider preference and deliver excellent per- formance for a given set of conditions.
Page 129 SUSPENSION “Indy Select” Rear Shock Some snowmobiles are equipped with the Indy Select/Select AFX rear shock, which allows the driver to make adjustments to the compression valving of the rear shock by turning the screw located near the base of the shock. Adjustment Locate the adjustment screw near the base of the shock.
Page 130 SUSPENSION “Indy Select” Rear Shock Turn spring clockwise Xtra-12 Type to increase preload Turn screw clockwise to tighten compression (stiffen) Xtra-10 Type Adjustment Screw Torsion Spring Adjustment Block (Low Setting Shown)
Page 131 SUSPENSION Front Torque Arm Limiter Strap Adjustment One method of changing ski-to- Xtra-12 snow pressure is to change the Type length of the front torque arm limiter straps using the holes provided. The limiter strap is normally mounted in the fully ex- tended position.
Page 132 SUSPENSION Suspension Set Up A decal outlining rear suspension set up options is located either on the hood or the clutch cover of your machine. These decals provide a guideline to be used for initial suspension set up. Your set up may vary based on your desired riding style. Xtra-12 Rear Suspension Adjustments The primary rear suspension adjustments on Xtra-12 models are the compression valving on both rear suspension shocks, the front track spring preload and the rear...
Page 133 SUSPENSION Front Rear Scissor Stop (FRSS) The purpose of the front rear scissor stop (FRSS) is to control the bump attitude of the rear suspension. As the front torque arm (FTA) hits the bump, it forces the rear scissor to collapse a predetermined amount, depending on the FRSS block position.
Page 134 SUSPENSION Front Rear Scissor Stop (FRSS) To adjust the FRSS compress the rear portion of the rear sus- FRSS shown in high position, pension until the rear scissor as indicated by dot on stop Rear pivots away from the FRSS. scissor Turn adjuster to desired posi- tion.
Page 135 SUSPENSION Xtra-12 Rear Rear Scissor Stop (RRSS) The RRSS on Xtra-12 type suspensions is not adjustable. Xtra-10 Rear Rear Scissor Stop (RRSS) The RRSS controls weight transfer RRSS - low from the skis to the rear suspension. position It also influences the stiffness of the shown ride by controlling the amount of cou- pling action between the front and rear...
Page 136 SUSPENSION Torsion Spring Adjustment - Xtra-12 Type Torsion spring preload is adjusted by turning the two position cam (A) on the short leg of the spring as shown with the engine spark plug tool. This adjustment is easier if the long spring leg is lifted over the roller and re- placed after the cam is properly posi- tioned.
Page 137: Suspension Performance Tips
SUSPENSION Suspension Performance Tips Generally, rider weight determines the position at which the spring preload should be set. However, this may vary with riding style. With a little experimentation, each rider can find his or her best set-up. Remember, the adjustments are easy to make, involve very little time or effort, and greatly affect the ride.
Page 138: Suspension Coupling
SUSPENSION SUSPENSION COUPLING On all Polaris snowmobile rear suspensions there are two torque arms that control the movement of the rail beam. Prior to the advent of “Suspension Coupling”, these torque arms could move independently of each other. Rear suspension “coupling” links the movement of the front and rear torque arms to each other, much like an anti-roll bar links the left hand and right hand front suspension skis to each other.
Page 139: Suspension
SUSPENSION REAR REAR SCISSOR STOP (RRSS) - ATTRIBUTES Moving the RRSS to a higher position or forward hole will have the following affects on the suspension: D Weight transfer will be reduced. D Chatter bump ride will improve. D Bottoming of the rear torque arm will be reduced. D Rear suspension action will become “stiffer.”...
Page 140: Troubleshooting
TROUBLESHOOTING Suspension Troubleshooting - - Models with X-12 Problem Solution Rear suspension bottoms too easily -Check to be sure FRSS block is in highest position -Adjust torsion spring blocks to highest posi- tion -Adjust coil over spring on front track shock to increase preload - -Change torsion springs to .421 diameter (on 121″...
Page 141 TROUBLESHOOTING Suspension Troubleshooting - - Models with X-12, 133″ Problem Solution Rear suspension bottoms too easily -Check to be sure FRSS block is in highest position -Adjust torsion spring blocks to highest posi- tion -Adjust coil over spring on front track shock to increase preload, replace front track spring with overload kit #2871439 -Change to stiffer shock valving on Indy Select...
Page 142 TROUBLESHOOTING Suspension Troubleshooting - - Models with X-10 Problem Solution Rear suspension bottoms too easily -Increase torsion spring preload -Increase rear shock compression valving by turning screw clockwise (if equipped with op- tional Indy Select shock) - -Change to heavier valving (if equipped with Fox™...
Page 143 TROUBLESHOOTING Suspension Troubleshooting - - Models with X-10 Problem Probable Cause Solution Harsh drive clutch Drive belt worn or too Replace. engagement narrow Excessive belt/sheave CONTACT YOUR DEALER. clearance Drive belt turns Wrong belt for applica- Replace. over tion Clutch alignment out Adjust alignment offset.
Page 144 TROUBLESHOOTING Belt Wear/Burn Belt Wear/Burn Diagnosis Belt Burning: Causes Solutions Driving at low RPM Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up Warm engine at least 5 minutes. Take drive- belt off the machine in extremely cold weath- er, and warm it up.
Page 145 TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine op- Drive clutch binding a. Disassembly of drive clutch required to in- erating RPM during spect shift weights for wear and free opera- acceleration or tion.
Page 146: Troubleshooting
TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Engine does not Seized engine CONTACT YOUR DEALER. Seizure is a re- turn sult of poor lubrication, inadequate fuel supply, broken parts, or improper cooling. Hydrostatic lock (fuel CONTACT YOUR DEALER to correct cause. has entered crank- Drain plug(s) located on lower crankcase for case while vehicle...
Page 147: Accessories
ACCESSORIES Accessories There are a wide range of accessories available for Polaris snowmobiles. From Map Lights to electric start, Polaris has the accessories that will make your ride even more pleasurable. Contact your dealer for a list of accessories available for your machine. NOTE: Accessory tether switch available for all models - PN 2870668.
Page 148: Service And Warranty
SERVICE AND WARRANTY INFORMATION Polaris Anti-Theft System The Polaris anti-theft system monitoring program (PATS) is designed to aid owners of registered snowmobiles in recovery of their machines, if stolen. Administration Polaris snowmobile owner reports theft. A. In addition to notifying the proper law enforcement officials, the owner must call the Polaris warranty department in the United States and Canada.
Page 149: Warranty
WARRANTY LIMITED WARRANTY Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078, gives a ONE YEAR LIMITED 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 which are covered by this warranty.
Page 150 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRAN- TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if incon- sistent with controlling state law.
Page 151 WARRANTY Polaris Extended Service Contract Polaris now is offering an extended engine service contract which provides the fol- lowing benefits: Additional engine protection beyond the original twelve month warranty. Backed by the strength of Polaris - no third party involvement. Repairs use only genuine top quality Polaris parts.
Page 152 WARRANTY Polaris Extended Service Contract Coverage, Cont.: Oil injection system coverage is limited to the control module, sensors, solenoids, pump, and throttle cable switch. Cooling system coverage is limited to the water pump assembly and compo- nents, fan, fan bearings, temperature sensor, gasket and seals. Non-wear related carburetor parts are covered.

Polaris 2000 Universal Snow Owner's Safety And Maintenance Manual

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