Polaris 2008 User Manual

7SAFETYOperator SafetyFollow the recommended maintenance program beginning on page 66 of this manual to ensure that all critical components on the sno

97MAINTENANCETrack MaintenanceTrack Tension4. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to th

98MAINTENANCETrack Maintenancen Track AlignmentPeriodically check that the track is centered and running evenly on the slide rails. Misalignment will

99MAINTENANCESteering SystemSteering Inspection and AdjustmentEach week, or before a long ride, check all steering system fasteners and tighten if nec

100MAINTENANCESteering SystemSki AlignmentWith the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measur

101MAINTENANCESteering Systemn Ski SkagsCheck skags before each use of the snowmobile to ensure positive steer-ing characteristics. Skags must be repl

102MAINTENANCESteering Systemn Rail Slide WearMeasure slide thickness at several points along the rail. Have your dealer replace the slide when it&ap

103MAINTENANCEDaily StorageAt the end of each ride, park the snowmo-bile on a level surface and support it at the rear with an appropriate track stand

104MAINTENANCEExtended StorageBearingsGrease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar hi

105MAINTENANCEExtended StorageElectrical ConnectionsReplace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured

106POLARIS PRODUCTSPart No. DescriptionEngine Lubricants2870791 Fogging Oil (12 oz. Aerosol)2871098 Premium 2-Cycle Engine Oil (qt.)2871097 Premium 2-

8SAFETYOperator SafetyStay Clear of TrackYour snowmobile is propelled by a revolving track that must be partially exposed for proper operation.Stay Cl

107TROUBLESHOOTINGEngine TroubleshootingUnless you have experience and training in two-cycle engine repair, see your dealer if technical problems aris

108TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionNoise in drive sys-temBroken drive clutch components• SEE YOUR DEALER.Bearing f

109TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionEngine turns but fails to startFaulty ignition • Install new spark plug(s). If

110TROUBLESHOOTINGIQ Suspension TroubleshootingProblem SolutionRear suspension bot-toms too easily • Adjust torsion spring preload to achieve proper s

111TROUBLESHOOTINGDrive Belt TroubleshootingBelt Wear/Burn DiagnosisCauses SolutionsDriving at low RPM • Drive at higher RPMs. Gear the machine down.

112WARRANTYService and Warranty InformationObtaining Service and Warranty AssistanceRead and understand the service data and the Polaris warranty info

113WARRANTYService and Warranty InformationPolaris Anti-Theft SystemThe Polaris anti-theft system (PATS) monitoring program is designed to aid owners

114WARRANTYLimited WarrantyPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-ITED WARRANTY on all components of the Polar

115WARRANTYLimitations of warranties and remediesALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FI

116WARRANTYConditions and ExclusionsIn order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if ap

9SAFETYOperator SafetyRiding ApparelBe prepared, be warm and be com-fortable when riding. Be aware of the weather forecast, especially the wind-chill

117WARRANTYPolaris Second Year Engine Service ContractSecond Year Engine Service Contract is standard on all eligible new and unused snow-mobiles that

118WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

119WARRANTYSnowmobile Engine Emissions Limited WarrantyThis snowmobile engine emissions limited warranty is in addition to the Polaris stan-dard limit

120WARRANTYSnowmobile Engine Emissions Limited WarrantySome states do not allow limitations on how long an implied warranty lasts, so the above limita

121MAINTENANCE LOGPresent this section of your manual to your dealer each time your snow-mobile is serviced. This will provide you and future owners

122MAINTENANCE LOGDATE MILES(KM)TECHNICIAN SERVICE PERFORMED / COMMENTS

123MAINTENANCE LOGDATE MILES(KM)TECHNICIAN SERVICE PERFORMED / COMMENTS

124INDEXAAccessories . . . . . . . . . . . . . . . . . . . 39Adjustable Headlights . . . . . . . . . . . 27Air Pollution . . . . . . . . . . . .

125INDEXLLights . . . . . . . . . . . . . . . . . . . . . 88-89Limiter Strap Position . . . . . . . . . . . . 34Low Oil Indicator Light . . . . . .

126INDEXTTrack Tension . . . . . . . . . . . . . . 32, 96Track Warm-Up. . . . . . . . . . . . . . . . 54Track Warning . . . . . . . . . . . . . .

10SAFETYOperator SafetySurvival PreparationFor your safety, always ride in a group of other snowmobilers. Always tell someone where you're going

11SAFETYOperator SafetyDisabled OperatorsSafe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cogn

12SAFETYOperator SafetyDriver AwarenessSlow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobilin

13SAFETYOperator SafetyAvalanchesSnowmobilers should always be properly trained and equipped before traveling in mountainous terrain:• Take an avalanc

14SAFETYOperator SafetyIce and Snow Build-upBefore driving, manually turn the skis to the left and right to be sure ice and snow are not interfering w

15SAFETYOperator SafetyDriving DownhillWhen riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply j

16SAFETYOperator SafetyDriving in Hilly TerrainUse extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight

17SAFETYOperator SafetyDrive BeltDo not operate the engine with the drive belt removed.Any servicing that requires operation without a belt must be pe

18SAFETYOperator SafetyInadequate Snow ConditionsSince snow provides the only lubrication for the power slide suspension and, on liquid cooled models,

19SAFETYOperator SafetyDriving ResponsiblyEvery snowmobile handles differently, and even the most docile condi-tions may become dangerous if operators

20SAFETYOperator SafetyWindchill/Temperature ChartsThe following information is provided to help you determine when tem-peratures become dangerous for

21SAFETYSafety Decals and LocationsWarning decals have been placed on the snowmobile for your protec-tion. Read and follow the instructions of the dec

22SAFETYSafety Decals and LocationsTrack WarningThe track warning decal is on the rear of the tunnel:Stay clear of track. Do not sit on seat back. E

23SAFETYSafety Decals and LocationsReverse WarningThe reverse warning decal is located on the console below the wind-shield:WARNINGReverse operation,

24SAFETYSafety Decals and LocationsOperation Warning• To avoid serious injury or death, read and understand all warnings and the Owner's Manual b

25FEATURES1. Hood2. Headlight3. Windshield4. Handlebar5. Seat6. Seat Storage Compartment7. Taillights8. Rear Bumper9. Snow Flap10. Suspension11. Track

26FEATURES1. Fuel Filler Cap/Dipstick2. Recoil Starter Handle3. High Temperature Indicator4. Reverse Indicator5. Headlight Adjuster6. Speedometer7. En

WARNINGRead, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.Failure to follow the safe

27FEATURESFuel ValveThe fuel valve is located under the hood. Turn the fuel valve off when-ever the snowmobile is stored or parked.1. Turn the valve c

28THE PERFECT FITFront Suspension AdjustmentsIndependent Front Suspension (IFS)Break in the suspension for about 150 miles (240 km) before making any

29THE PERFECT FITFront Suspension AdjustmentsShock Spring PreloadIncreasing spring preload will increase ski-to-ground pressure. Decreasing spring pre

30THE PERFECT FITFront Suspension AdjustmentsShock ValvingShocks can be revalved if spring preload alone isn't sufficient and fur-ther adjustment

31THE PERFECT FITRear Suspension AdjustmentsRider weight, riding style, trail conditions, and vehicle speed all affect suspension action.Each rear sus

32THE PERFECT FITRear Suspension AdjustmentsSuspension Performance Tips• Rider weight usually determines the position at which the spring pre-load sho

33THE PERFECT FITRear Suspension AdjustmentsInitial Spring Preload Setting (Sag Method)To set up the rear suspension torsion spring preload, measure t

34THE PERFECT FITIQ Rear Suspension AdjustmentsTorsion Spring PreloadTo adjust rear torsion spring preload, rotate the three-position cam using the en

35THE PERFECT FITIQ Rear Suspension AdjustmentsRear Shock Compression Damping (Premium Shocks)Turn the adjustment knob on the shock reservoir to make

36THE PERFECT FITIQ Rear Suspension AdjustmentsSuspension CouplingOn all Polaris snowmobile rear suspensions, there are two torque arms that control t

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris enthusiasts. Be sure to visit us online at www.pol

37THE PERFECT FITIQ Rear Suspension AdjustmentsSuspension CouplingRear To Front Coupling and the Rear Rear Scissor Stop (RRSS)The rear rear scissor st

38THE PERFECT FITIQ Rear Suspension AdjustmentsWeight Transfer During AccelerationThe preferred method for controlling weight transfer during accelera

39THE PERFECT FITAccessoriesPolaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable.Use only Polaris part

40THE PERFECT FITHandlebar AdjustmentsWhen making handlebar adjustments, always be sure the handlebars, brake lever and throttle lever operate smoothl

41THE PERFECT FITHandlebar AdjustmentsHandlebar AngleFollow these steps to adjust handlebar angle at the handlebar block.1. Remove the handlebar cover

42THE PERFECT FITTraction ProductsStudsBefore equipping your machine with traction products, be aware of the laws in your area pertaining to the use o

43THE PERFECT FITTraction ProductsnCarbide SkagsA skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile a

44PRE-RIDE INSPECTIONSPre-Ride ChecklistInspect all items on the checklist for proper operation or condition before each use of the snowmobile. Proce

45PRE-RIDE INSPECTIONSBefore Starting the EngineRead and Understand Your Owner's ManualRead the Owner's Manual completely and refer to it of

46PRE-RIDE INSPECTIONSBefore Starting the Enginen BrakesAlways check the following items for proper operation before starting the engine.Brake Lever T

2POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-tries Inc.Copyright 2007 Polaris Sales Inc. All information contained with

47PRE-RIDE INSPECTIONSBefore Starting the Enginen Parking Brake Lever LockUse the parking brake lever lock only when you want the machine to remain st

48PRE-RIDE INSPECTIONSBefore Starting the Enginen Steering SystemBefore driving, manually turn the skis to the left and right to be sure ice and snow

49PRE-RIDE INSPECTIONSBefore Starting the Enginen Hood LatchesThe hood of the snowmobile protects the operator from moving parts as well as aiding in

50PRE-RIDE INSPECTIONSStart the Engine and CheckBefore starting the engine, always refer to all safety warnings pertaining to snowmobile operation. N

51OPERATIONStarting the Engine1. Turn the fuel valve on. See page 27.2. Turn the key to the ON position.3. Pull the engine stop switch up to the RUN p

52OPERATIONEmergency StoppingThe following chart lists methods for stopping the snowmobile in the event of an emergency. See page 60 for more informa

53OPERATIONEngine Break-InOil Injection SystemAlways check and fill the oil tank when refueling. See page 57.Oil RecommendationsThis snowmobile is eq

54OPERATIONTrack Warm-UpFollow these steps to ensure proper warm-up of the engine, drive train and track.1. Use an appropriate stand to securely sup-p

55OPERATIONFuelWARNINGGasoline is highly flammable and explosive under certain conditions.• Always exercise extreme caution whenever handling gasoline

56OPERATIONFuelFor peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor-ma

3TABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4This section contains helpful information for owners and dri

57OPERATIONn OilLow Oil Indicator LightThe low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bott

58OPERATIONCarburetionProper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing f

59OPERATIONCarburetionJetting GuidelinesChanges in altitude and temperature affect air density, which is the amount of oxygen available for combustion

60OPERATIONn Engine Stop SwitchPush down on the engine stop switch (+) to ground out the ignition and stop the engine quickly. Pull the switch up to t

61OPERATIONThrottle LeverIf the engine stops abruptly when the throttle lever is released:1. Turn the ignition switch to OFF.2. Visually inspect the t

62OPERATIONElectronic Reverse (PERCt)Electronic reverse will activate only if the engine RPM is below 4000.Engaging Reverse1. Stop the snowmobile and

63OPERATIONTo w i n gDo not use the front bumper to pull or drag the snowmobile. The front bumper is not designed for this type of use and may detach

64MAINTENANCEEmission Control InformationAny qualified repair shop or qualified person may maintain, replace, or repair the emission control devices o

65MAINTENANCEEmission Control InformationOwner's ResponsibilitiesPlease read the Snowmobile Engine Emissions Limited Warranty on page 119, and re

66MAINTENANCEPolaris Recommended Maintenance ProgramTo ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenanc

4INTRODUCTIONVehicle Identification NumbersRecord your snowmobile's identification numbers and key number in the spaces provided. Remove the spa

67MAINTENANCEPeriodic Maintenance Interval TableThe following chart is a guide based on average riding conditions. You may need to increase frequency

68MAINTENANCEPeriodic Maintenance Interval TableItem See PageFrequency150 mi.(240 km)500 mi.(800 km)1000 mi.(1600 km)2000 mi.(3200 km)Pre-SeasonBRAKES

69MAINTENANCEPeriodic Maintenance Interval TableI - Inspect (clean, adjust, tighten, lubricate, replace if necessary)C - Clean R - Replace L - Lubrica

70MAINTENANCELubricationFront SuspensionThe front suspension does not require lubrication.Rear SuspensionLubricate the suspension pivot shafts with Po

71MAINTENANCELubricationDriveshaft BearingInject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the in

72MAINTENANCELubricationn Chaincase OilCheck the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 66. The si

73MAINTENANCELubricationChaincase OilOil Change 1. Position the vehicle on a level surface.2. Remove the drain plug (4) and drain the oil into a drain

74MAINTENANCESpark PlugsA new engine can cause temporary spark plug fouling due to the preser-vative added during the assembly process. Avoid prolong

75MAINTENANCESpark PlugsSpark Plug ConditionNormal PlugThe normal insulator tip is gray, tan or light brown. There will be few combustion deposits.

76MAINTENANCEIntake FiltersThe intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam f

5INTRODUCTIONPreservation of the EnvironmentPolaris is committed to supporting an environmental education cam-paign. We encourage governments to adop

77MAINTENANCEFuel PumpAll fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump.Fuel Filter/Fu

78MAINTENANCECarburetorThe number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not nece

79MAINTENANCECarburetor Water/Sediment TrapMost Polaris snowmobiles contain patented carburetor bowl water/sedi-ment traps located at the bottom of ea

80MAINTENANCECooling SystemCoolantThe coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which w

81MAINTENANCECooling SystemCoolant High Temperature Indicator LightThe high temperature indicator light will illuminate when engine cool-ant temperatu

82MAINTENANCECooling SystemBleeding the Cooling System Use of a non-standard pressure cap will not allow the recovery system to function properly. If

83MAINTENANCECooling SystemBleeding the Cooling System6. Stop the engine and check the coolant bottle level. Fill as required.7. Feel the heat exchan

84MAINTENANCEDrive Chain TensionCheck drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven cl

85MAINTENANCEBrakesn Hydraulic Brake InspectionInspect brake lever travel before each use of the snowmobile. See page 46.Brake pads must be replaced w

86MAINTENANCEBrakesBrake FluidThe brake fluid level can be seen through a plastic sight glass in the brake reservoir. If the fluid is sufficient, the

6SAFETYOperator SafetyThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these wor

87MAINTENANCEBrakesBleeding the Hydraulic Brake SystemAir in the hydraulic brake system will cause spongy brake lever action. Bleed the system before

88MAINTENANCELightsNOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life

89MAINTENANCELightsTaillight/Brakelight Replacement1. Remove the screws securing the taillight lens. Remove the lens.2. Push the bulb inward and turn

90MAINTENANCEClutch SystemPeriodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil b

91MAINTENANCEClutch Systemn Drive Belt ConditionPeriodically check the condition and tension of the drive belt, and always carry a spare. Inspect the

92MAINTENANCEClutch SystemDrive Belt Installation1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory be

93MAINTENANCEClutch Systemn Drive Belt DeflectionMeasure belt deflection with both clutches at rest and in their full neutral position.Place a straigh

94MAINTENANCEFall Tune-UpFor maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service te

95MAINTENANCETrack MaintenanceTrack LubricationThe slide rail needs snow for lubrication. Excessive wear indicates insufficient lubrication. A new r

96MAINTENANCETrack MaintenanceTrack TensionTrack adjustment is critical for proper handling. Always maintain cor-rect tension and alignment. NOTE: Te