Polaris 120 Indy v7 Owner's Manual PDF

Pages 97
Year 2015
Language(s)
English en
1 of 97
1 of 97

Summary of Content for Polaris 120 Indy v7 Owner's Manual PDF

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WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts... Be sure to visit us online at www... polaris... com for the latest news, new product introductions, upcoming events, career opportunities and more... Here at POLARIS we proudly produce an exciting line of utility and recreational products... Snowmobiles All-terrain vehicles (ATVs) Low emission vehicles (LEVs) RANGER utility vehicles VICTORY motorcycles GEM vehicles 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 weve ever pro- duced... For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owners manual... Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer (MSD) technician... Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction... Be sure to return to your dealership for all of your ser- vice needs during, and after, the warranty period...

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POLARIS is a trademark of POLARIS Industries Inc... Copyright 2014 Polaris Industries 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 discrep- ancies may result between the actual vehicle and the information presented in this publi- cation... Depictions and/or procedures in this publication are intended for reference use only... No liability can be accepted for omissions or inaccuracies... Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited... The original instructions for this vehicle are in English... Other languages are provided as translations of the original instructions... Printed in U... S... A... 2015 120 INDY Snowmobile Owner's Manual P/N 9925112

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Adult Section ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25 Pre-Ride Check... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25 Operation Warnings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29 Component Identification... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 40 Break-In Period ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42 Operation... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43 Emission Control Information ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 48 Maintenance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49

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WELCOME Dear Parents: We believe your children should have the opportunity to enjoy The Way Out experience along with you... We've provided this owner's manual to assist you and your children in learning about the safe operation and care of your new POLARIS snowmobile... Please review the information in this manual with any child who may operate the snowmobile... Help your children learn to operate the snowmobile with safety as a top prior- ity... Help them also learn to show respect for our environment and for the rights of others while operating the snowmobile... Since the operator will be a newcomer to the exciting winter sport of snowmobiling, please be sure he/she understands this information before riding the snowmobile... Never allow a child to operate the snowmobile without adult supervi- sion... This owner's manual contains instructions for minor maintenance, but major repairs are covered in the POLARIS Service Manual and should be performed by a factory certified Master Service Dealer (MSD) tech- nician... Be sure to return to your dealership for all of your service needs during, and after, the warranty period... The preventive maintenance program outlined in this manual is designed to ensure that all critical components on your child's snowmo- bile are thoroughly inspected at various intervals... If you have any ques- tions about the snowmobile, contact a POLARIS dealer for assistance... See page 82 for the part numbers of POLARIS products...

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WELCOME Dear Children: Before you ride your new POLARIS snowmobile, there are some important things that you need to know... Your parents and POLARIS want you to enjoy riding your new snowmobile, and that's why you need to read and understand the information in your owner's manual... Ask your parents to explain anything you don't understand, and pay close attention to the warnings and instructions you read... Your safety and the safety of others is the most important thing to think about at all times... As the driver of the snowmobile, you must learn how to keep yourself and those around you safe while you're riding... So read your manual, and then enjoy riding your new POLARIS snowmobile!

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PARENTS: Do not allow anyone under the age of six (6) to operate this machine... Review the information in this manual with any child who may be operating the snowmobile... It is up to you to teach any operator the proper and safe way to ride a snowmobile... You must set boundaries and adhere to them, keeping the operator's safety foremost in your mind... Never allow a child to operate this machine without adult supervision... These units are not designed for adult use... Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded... Never exceed the maximum rider weight capacity... See page 80... CHILDREN: Before you ride your new POLARIS snowmobile, there are some important things that you need to know... Your safety and the safety of others is the most important thing to think about at all times... As the driver of the snowmobile, you must learn how to keep yourself and those around you safe while you're riding... Pay attention when you see this symbol:

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Noise One of the most publicized subjects with regard to snowmobiles is noise... The Society of Automotive Engineers (SAE), which is the stan- dard-setting body for snowmobiles, has recommended that snowmobiles conform to prescribed sound levels... This POLARIS snowmobile has been engineered to conform to these SAE standards... In order to be meaningful, all regulations require the cooperation of the snowmobile owner... Muffling systems, designed to reduce noise levels, should not be altered or removed... Snowmobile drivers must be aware that they have a public responsibility to operate their snowmobiles with concern for others... As a snowmobile operator you may not realize the sound of your snowmobile may annoy non-snowmobilers... We are attempting to do our part through the manufacture of quieter machines, and we also ask your help in the effort to further reduce the impact of noise...

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INTRODUCTION Preservation of the Environment Environmental Protection As part of the continuing environmental education campaign, we are encouraging state and provincial governments across the snowbelt to adopt rigorous safety training programs which also encourage protection of our environment, wildlife and vegetation... Snowmobile clubs and other organizations are working together to protect our environment... It is very important that we encourage them as well as become actively involved ourselves... Protect and preserve your right to ride by joining your local trail

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INTRODUCTION Vehicle Identification Numbers Record your snowmobile's identification numbers in the spaces provided...

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SAFETY The following signal words and symbols appear throughout this manual and on your vehicle... Your safety is involved when these words and sym- bols are used... Become familiar with their meanings before reading the manual...

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Equipment Modifications All POLARIS snowmobiles have been designed and tested to provide safe operation when used as directed... Failure of critical machine compo- nents may result from operation with any modification; especially those that increase speed or power... There is a significant possibility of loss of control at higher speeds... We are concerned for the safety of our customers and for the general public... Any modifications to the original equipment of the vehicle cre- ate a substantial safety hazard and increase the risk of bodily injury... Therefore, we strongly recommend that consumers do not install on a POLARIS snowmobile any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes... The warranty on your POLARIS snowmobile is terminated if any equip- ment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power...

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SAFETY Maintenance Program This snowmobile is not a toy... The information in this manual is pro- vided to aid you in its safe operation... For the safety of the operator, always make sure that the snowmobile is in excellent operating condition at all times... We strongly recommend that the operator, as well as an adult, check major and vital safety com- ponents before each use of the vehicle... We also recommend that you strictly follow the maintenance schedule outlined in this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at various mileage intervals...

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SAFETY Safety Labels Safety and warning labels have been placed on the vehicle for the operator's protection... Make sure the operator understands the information on all labels... If any label becomes illegible or comes off, contact your POLARIS dealer for a replacement... Replacement safety labels are provided by POLARIS at no charge... The part number is printed on the label... General Warning Label WARNING Read and understand warnings and the

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Throttle Lever The throttle lever makes your snowmobile go forward when you press it with your thumb... Before you drive your snowmobile, always make sure the throttle lever does not stick... Read more about it on page 19...

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Tether Strap/Switch Always attach the tether strap to your body and to the switch on your snow- mobile every time you drive... If you fall off your snowmobile, the tether strap will pull away from the switch and the engine will stop... When you attach the strap to your body, you can clip it to a loop on your cloth- ing, or you can wrap the strap around your right wrist and attach the clip to the strap...

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YOUTH SECTION Know Your Snowmobile Let's learn more about the parts of your snowmobile before we learn about riding...

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Seat and Storage When the engine is stopped, you can take the seat cushion off and put things under the seat... Push the two seat latches in and pull the seat up to remove it... Always put the seat back on and make sure the latches are locked in place before riding again...

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Let's review the 2 ways to stop your snowmobile:

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YOUTH SECTION Pre-Ride Check You're almost ready to have an adult start your snowmobile... But first you must do a PRE-RIDE CHECK to make sure the snowmobile is safe to ride... Every time you want to ride your snowmobile, always have an adult help you check these things before you start the engine... Throttle Lever Squeeze the throttle lever toward the handlebar and then let it go... The lever should go right back to where it was before you squeezed it... If it goes back slowly or stays close to the handlebar, you have a sticky throt- tle... This means that something is wrong or broken...

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Have an adult check the gas level to see if your snowmobile needs more gas... Children should never open the gas cap or add gas... Always have an adult do this... Before anyone adds gas to your snowmobile they must read the instructions and warnings on page 43 in this Owner's Manual... Oil Level Have an adult check the engine oil level when the engine is cold... The engine is very hot after it has been running... It could burn your skin... Children should never check the oil... Always have an adult do this... 2 Ways to STOP Always check to make sure that BOTH WAYS TO STOP are working the way they should... Do you remember what they are? Follow these steps: 1... Start the engine... Push the stop switch down... The engine should

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Your snowmobile is made for only one rider... Never carry a passenger... A passenger will make the snowmobile harder to drive... You may lose control and hurt yourself and your passenger... Never pull anything behind your snowmobile... Make sure you know where you're going to drive before you start the engine... Make sure the area is safe all around your snowmobile... Never ride alone... An adult should always be watching you in case you need help... Always drive where an adult can see you... Never ride on public trails... When you're a beginner, always stay on level ground... Don't ride your snowmobile on roads or over railroad tracks... Your snowmobile makes noise that will keep you from hearing cars, trucks or trains that may be coming toward you... Stay away from fences... Make sure you know where all the fences are before you ride... If you drive into a fence, you could get hurt... Don't ride at night... The headlight on your snowmobile is there only so others can see you driving during the day...

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Always wear the right kind of clothing when you ride your snowmo- bile... Always wear a helmet with a face shield or goggles... Wear a warm jacket and snowpants... Make sure your clothing fits properly... Tight clothing could keep you from moving easily... Baggy clothing could hang down and get caught in the track or another moving part... Never wear a long scarf... Wear warm snowmobile boots and gloves, and make sure your boot laces are tied... If you have long hair, tie it up or put it inside your helmet or jacket... Learn if there are lakes, rivers, ponds and ditches in your driving area... Stay away from them... Never ride on frozen water... Your snowmobile could fall through the ice into the water and you could drown or freeze to death... Always be alert and pay attention to where you're driving... Always watch out for objects or people in your driving area and stay a safe distance away from them...

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Always sit down when you drive... Keep both hands on the handlebars... Keep both feet on the running boards... Never follow another snowmobile too closely... Always allow lots of space to stop your snowmobile... Ride your snowmobile only where you know it's safe to drive and where you have permission to drive... Always be a polite driver... Dont drive through the flower garden or over small trees... Always attach the tether strap to your body and to the switch on your snowmobile every time you drive...

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YOUTH SECTION Riding Rules Learn how to use your hands and arms as signals... Use these signals to let others know when you are getting ready to turn or stop your snow- mobile... Read and understand your Owner's Manual...

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Inspect all items on the checklist for proper operation or condition before each use of the snowmobile... Procedures are outlined on the refer- enced pages... These checks should become automatic for the child before each ride... As the adult teacher, you must instill in all riders the importance of performing this Pre-Ride Check before they operate the snowmobile...

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Check the throttle for proper operation When checking the throttle, make sure the throttle lever compresses evenly and smoothly... When the lever is released, it should immediately return to the idle position without binding or hesitation... If the throttle does not function smoothly, do not start the engine... Have the throttle serviced before operating the snowmobile... Check the brake for proper operation Squeeze the brake lever toward the handlebar... When the lever is released, it should return to its original position smoothly... If the lever hesitates or seems sticky, do not start the engine... Have the brakes ser- viced before operating the snowmobile... See page 31 for brake lever travel specifications... Check for proper operation of the steering system Check for proper operation of the steering system... Manually turn the skis completely to the right and to the left... If difficulty is encountered, check for ice and snow buildup that may be obstructing the steering linkage... Make sure all greaseable components are properly lubricated...

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ADULT SECTION Pre-Ride Check Check the throttle safety switch Test the throttle safety switch system on a daily basis before the vehicle is used... With the engine idling, hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration... Apply a slight amount of throttle opening... A properly functioning switch must shut down the engine... The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valve does not return to the normal closed position... If excessive play develops in the throttle cable, the safety switch may be activated and will prevent the engine from starting... If the engine doesn't start and throttle safety switch malfunction is suspected, return the machine to an authorized POLARIS dealer for service...

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ADULT SECTION Pre-Ride Check Inspect the track Driving for extended periods of time with marginal lubrication could severely damage the track... Driving on icy trails or driving when there is little or no snow are two examples of situations that would provide mar- ginal lubrication and are not recommended... Do not operate the snowmo- bile with a damaged track...

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WARNING The drive chain guard is designed to protect the operator from metal parts in the event of a drive chain failure... Although the chance of failure is extremely remote, do not defeat the purpose of the guard by removing it... It is provided for the safety of the child...

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WARNING Safe operation of this rider-active vehicle requires good judgement and physi- cal skills... Persons with cognitive or physical disabilities who operate this vehi- cle have an increased risk of overturns and loss of control, which could result in serious injury or death...

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ADULT SECTION Operation Warnings Check brake lever travel Depress the brake lever fully... Measure the clearance between the lever and brake block... Clear- ance should be no more than 3/4 (1... 9 cm)... Excessive travel indicates a need to adjust the brake cable... Refer to the mechanical brake adjustment information on page 56... Secure the hood The hood of the snowmobile protects the operator from moving and hot parts as well as aiding in sound emission control and other functions... Never operate a snowmobile with the hood open or removed... Check lights Start the engine and ensure that both the headlight and taillight operate...

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ADULT SECTION Operation Warnings Check surroundings Make sure the operation area is clear of obstacles and bystanders... Some sideways movement is possible when the snowmobile first begins to move, and debris may be thrown by the track... Teach the operator to check the operating area before riding... Sit properly on the snowmobile Operating a snowmobile requires skill and balance for proper control... An improper position can reduce the child's ability to control the snow- mobile... The riding position may vary as the operator becomes more skilled, but under most conditions the proper position is to be seated with both feet on the running boards, in a comfortable position for proper throttle, brake and steering control...

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ADULT SECTION Operation Warnings Always wear clothing designed for snowmobiling Always make sure the operator is wearing an approved helmet and eye protection... Do not allow the child to wear loose clothing or long scarves because they can easily become entangled in moving parts... If your child has long hair, be sure it is always tied up securely and tucked into the helmet or jacket... Helmet Wearing a helmet can prevent a severe head injury... Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards... Approved helmets in the USA and Canada bear a U... S... Department of Transportation (DOT) label... Approved helmets in Europe, Asia and Oceania bear the ECE 22... 05 label... The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval... The approval number and serial number will also be displayed on the label... Eye Protection Do not depend on eyeglasses or sunglasses for eye protection... When- ever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield... POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87... 1, or CE... Make sure protective eye wear is kept clean...

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Know limitations of machine and skills of driver The operator should be aware that most areas have laws governing snowmobile operation and that these laws should be followed... They have been established for the protection of all snowmobile riders... Many local organizations offer a snowmobile safety course for children... Check with local authorities to locate providers of this service... This vehicle is intended for daylight use only... Check both the headlight and taillight to ensure proper operation... IMPORTANT: The headlight and taillight are intended only to increase the visibility of the snowmobile during daylight operation... Do not operate this snowmobile in the dark...

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ADULT SECTION Operation Warnings Instruct all operators Teach all young drivers to always be alert and to pay attention to the driving area ahead... When teaching inexperienced operators to ride, set up a predetermined course... Establish boundaries and make sure all operators know and understand them... Make sure they know how to drive and control the snowmobile before you allow them to drive longer supervised distances... Teach them proper snowmobile courtesy... It's a good idea to predetermine some hand signals as a way to communicate with a child while giving instruction... It may be difficult for a child to hear your voice over the sound of the snowmobile and through a helmet... Teach the operator that the sound of the engine will make it difficult to hear the sound of approaching vehicles... Do not allow a child to operate the snowmobile on or near roads and railroad tracks... Teach operators what it means to drive defensively... Never tailgate and always allow ample stopping distances... Be alert for obstacles Wire fences are a serious hazard... Teach operators to always be on the alert for fences... Single strands are especially dangerous, since there can be a great distance between posts... Ground wires on utility poles are also difficult to see... Teach operators to reduce speed when traveling near poles, posts or other obstacles... Check the weather Extremely cold weather can cause frostbite and/or hypothermia... Always be aware of weather conditions, especially the windchill... See the table on page 39...

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Drive-Away from Parked When the snowmobile has been parked for more than a few hours, espe- cially overnight, the skis and track may freeze to the ground... Loosen the skis and track for the operator... You may have to apply extra throttle ini- tially to move the snowmobile... Teach operators not to be afraid of applying extra throttle in this situation, but make sure they understand that too much throttle could cause the snowmobile to lurch forward...

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Ice and Hard-Packed Surfaces Steering and braking control are substantially reduced when operating on hard surfaces, hard-packed snow or icy surfaces... Teach your child to reduce speed to maintain control in all driving conditions... If necessary, limit the maximum speed of the snowmobile as outlined on page 44... If ice or slippery conditions are unavoidable, use extreme caution and operate at speeds no faster than a walk... The skis need snow to help the snowmobile make turns... On hard surfaces the snowmobile will not make turns easily... It may be best to stop the engine, dismount, and man- ually move the front or rear of the snowmobile to change direction... Never make a sharp turn on a slippery surface... The snowmobile may skid out of control... Teach all operators to drive only in approved areas within the vision of the supervising adult...

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ADULT SECTION Operation Warnings Driving on Hills Traveling on hills is not recommended... A child may not be capable of maneuvering body weight as needed for operating on hills... If traveling on hills is unavoidable, teach your child to use extreme caution and obey the following proper operating procedures...

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8 3 0 -4 -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57 16 2 -2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 24 1 -3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 32 0 -4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67 40 -1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69 48 -1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70 56 -2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72 64 -2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73 72 -2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74 80 -3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75 88 -3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76 96 -3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

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ADULT SECTION Break-In Period Engine Break-In The break-in period for your new snowmobile is defined as the first ten hours of operation, or the time it takes to use the first two tanks full of gasoline... No single action on your part is as important as a proper break- in period... Careful treatment of a new engine will result in more efficient performance and longer life for the engine... NOTICE: Excessive heat build-up during the first three hours of operation will

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WARNING Gasoline is highly flammable and explosive under certain conditions... Always exercise extreme caution whenever handling gasoline... Always refuel with the engine stopped, and outdoors or in a well ventilated

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ADULT SECTION Operation Speed/Performance Regulation As the adult, you must teach the child the proper and safe way to ride a snowmobile... Set boundaries and adhere to them, keeping the child's safety foremost in your mind... Never allow the child to operate this vehi- cle without adult supervision... You can regulate the speed and acceleration of the snowmobile...

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ADULT SECTION Operation Starting the Engine Never start the engine before performing the Pre-Ride Check... See pages 19 and 25... 1... Pull the engine stop switch up to the RUN position... 2... Do not use the choke when starting a warm engine... If the engine is

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Daily Storage At the end of each ride, park the snow- mobile on a level surface... Support the rear with an appropriate track stand... The track should be suspended approxi- mately 4 (10 cm) off the ground... Cover the snowmobile with an appro- priate snowmobile cover...

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WARNING A loose track or flying debris could cause serious personal injury or death... Be sure the rear support is stable... Stand clear of the front of the machine and the moving track... Never hold the snowmobile up or stand behind it while perform- ing this procedure... Do not use too much throttle during warm-up or when the track is free-hanging...

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Emission Control Label Your snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa- tion hangtag... These items are required by U... S... Environmental Protection Agency regulations... The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover... The ECI label should not be removed, even after you purchase the snowmobile... You may remove the factory-installed emissions information hangtag, which is intended solely for your use in making a purchasing decision...

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ADULT SECTION Maintenance POLARIS Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual... Record maintenance and service in the Mainte- nance Log beginning on page 91... The recommended maintenance schedule for your snowmobile calls for a service and maintenance inspection at 50 hours, at 100 hours and at 150 hours... These inspections should be performed by a qualified service technician... All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, become the responsibility of the regis- tered owner... If, during the course of the warranty period, part failures occur as a result of owner neglect in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner... Personal safety is critical when attempting to service or make adjust- ments to your snowmobile... If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfort- able performing these tasks yourself, contact an authorized POLARIS dealer for service... NOTICE: Hot components can cause damage to plastic... Always make sure the

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ADULT SECTION Maintenance Periodic Maintenance Chart The following chart is a guide based on average riding conditions... You may need to increase frequency based on riding conditions... When inspection reveals the need for replacement parts, always use genuine POLARIS parts, available from your POLARIS dealer...

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Throttle cable pivot slug 58 X X X Lubricate steering post support bracket and pivot (aerosol)

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ADULT SECTION Maintenance Spark Plugs A new engine can cause temporary spark plug fouling due to the preser- vative added during the assembly process... Avoid prolonged idle speeds, which cause plug fouling and carbonization... Refer to the specifications section beginning on page 80 for recom- mended spark plug type and gap... NOTICE: Using non-recommended spark plugs can result in serious engine

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ADULT SECTION Maintenance Spark Plugs Normal Plug The normal insulator tip is gray, tan or light brown... There will be few combustion deposits... The electrodes are not burned or eroded... This indi- cates the proper type and heat range for the engine and the service... TIP:The tip should not be white... A white insulator tip indicates overheating,

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Exhaust System At approximately 50 hours, check the exhaust system for wear or dam- age... To inspect, allow the engine and exhaust system to cool completely... Open the hood and inspect the muffler and pipes for cracks or damage... Check for weak or missing retaining springs or damper/support grom- mets...

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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 failure... A lean mixture can be the result of fuel line restrictions or foreign matter in the carburetor... A mix- ture too rich (too much fuel, too little air) is also unfavorable because it can foul plugs and cause generally poor engine performance... All carburetors have been pre-set at the factory to the settings indicated by the shaded cells of the jetting chart on page 81... Higher altitude oper- ation may require different adjustment and settings... TIP:The number stamped in the end of the main jet indicates the jet size that

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ADULT SECTION Maintenance Brake Lever Travel Firmly depress the brake lever... Measure the clearance between the lever and brake block... If clearance is more than 3/4" (19 mm), adjust the brake cable as outlined below...

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6... The brake band is adjusted correctly when brake lever freeplay is 1/4- 3/8 (6-10 mm) and clearance between the brake lever and block with the lever fully depressed is no more than 3/4 (19 mm)... Torque the band bolt nut to 6 ft... lbs... (8 Nm)...

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Choke/Cable Lubrication Lubricate the choke slide and cables occasionally as shown... Operate the choke intermittently before turning the engine off... This draws moisture out of the choke plunger area and reduces the possi- bility of the choke becoming fro- zen...

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ADULT SECTION Maintenance Chain Tensioner Inspect the chain... Proper deflection is one inch (25 mm)... Adjust the chain if deflection is incorrect... 1... Loosen the nut on the chain tensioner... 2... Raise the tensioner until the correct deflection is attained... 3... Tighten the nut to 15-18 ft... lbs... (20-24 Nm)... TIP:When the chain has stretched to within 1/8" (3 mm) of the muffler mount

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ADULT SECTION Maintenance Driveline Lubrication TIP:Driveline noise is normal for this vehicle... To ensure long life of the snowmobile's driveline, lubricate as follows: Lubricate Point A every 15 hours of operation with a small amount of

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ADULT SECTION Maintenance Engine Oil Oil Recommendations POLARIS recommends the use of Performance Synthetic 4-Stroke oil (PS-4 or PS-4 Plus) for this engine... PS-4 has been specially formulated for use in 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... Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 50... Perform the break-in oil change after 20 hours of operation... Always change the oil any time it's contaminated with water, fuel or debris... NOTICE: Mixing brands or using a non-recommended oil may cause serious

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TIP:The oil will drain faster with the dipstick removed... 5... Allow the oil to drain completely... 6... Reinstall the drain plug and sealing washer... Torque to 10 ft... lbs...

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5... Measure the distance between wear surface of the track clip and the plastic slider at the point where the weight is hanging... Deflection at this point should be 3/4" (19 mm)...

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WARNING When performing the following checks and adjustments, stay clear of all mov- ing parts to avoid serious personal injury... Make sure the track contains no objects that could be thrown out while the track is rotating... Keep clear of track... This includes but is not limited to hands, tools, feet and clothing... Make sure no one is standing close to the machine while the track is rotating...

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WARNING When performing the following checks and adjustments, stay clear of all mov- ing parts to avoid serious personal injury... Make sure the track contains no objects that could be thrown out while the track is rotating... Keep clear of track... This includes but is not limited to hands, tools, feet and clothing... Make sure no one is standing close to the machine while the track is rotating...

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ADULT SECTION Maintenance Track Warm Up After storing your snowmobile outside overnight, warm up the track before driving the snow- mobile... This reduces drive clutch wear... 1... Support the rear of the

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WARNING Inspecting the track while the engine is running can result in serious per- sonal injury if the track should being to move... Never inspect the track with the engine running... Never hold the snowmobile up or stand behind it while rotating the track... A loose track or flying debris could cause serious personal injury or death...

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Track Lubrication Track failure, loss of vehicle control and braking ability can result from extended use of this vehicle on surfaces providing marginal lubrication between the slider and track guide clips... Examples of marginal lubrica- tion would include lakes without snow cover, icy trails and no-snow conditions... The slide rail is designed to operate in conditions with adequate snow cover in order to provide sufficient lubrication... Excessive wear indicates insufficient lubrication... A new slider can cause faster heat build up in limited lubrication than a used slider, resulting in excessive wear... TIP:Track damage or failure caused by operation on ice or poor lubrication con-

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Steering Adjustment With the handlebars in a straight ahead position, and with vehicle weight compressing the suspen- sion, measure from the straight edge of the skis at the center of the ski mounting bolt... The measure- ment between the skis at point X should be 1/8 (3 mm) greater than the measurement at point Y... TIP: If the skis are misaligned, we rec-

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upward to access the adjuster bolts... If additional room is required, unzip one of the handlebar pad zippers and roll the pad to the side...

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ADULT SECTION Maintenance Ski Skags The skag is a replaceable bar attached to the underside of the ski... The purpose of the skag is to assist in turning the snowmobile and to prevent the wearing away of the ski caused by contact with roads and other bare terrain... Check skags weekly to maintain positive steering characteristics... Replace skags when they are worn to half their original diameter... TIP:See the dealer track studding and skag chart for recommended skags...

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ADULT SECTION Maintenance Lubrication Recommendations Suspension To maintain rider comfort and to retard wear of the pivot shafts, lubri- cate the suspension pivot shafts with POLARIS Premium All Season Grease several times during the season and again before summer storage each year... Lack of lubrication will result in reduced performance and a less comfortable riding experience... TIP:The stars in the following illustration indicate lubrication points... A grease

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Electrical Connections Separate the electrical connector blocks and clean corrosive build-up from the connectors... Lubricate the blocks with dielectric grease and re- connect... Replace worn or frayed electrical wire and connectors... Be sure wiring harnesses are properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust components...

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ADULT SECTION Maintenance Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear- ance but it can also extend the life of various components... NOTICE: High water pressure may damage components... POLARIS recom-

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carburetor should be completely drained of gasoline... Observe all fire safety rules when draining the carburetor... Review the fuel-related warnings on page 43... To eliminate any fuel remaining in the carburetor, run the engine until it stops...

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ADULT SECTION Maintenance Storage Stabilize the Fuel Proper off-season preparation of the engine and fuel system is vital to the prevention of rust and corrosion formation on precision engine parts during storage... See page 82 for the part numbers of POLARIS products... 1... Fill the fuel tank with fresh fuel... 2... Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel

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ADULT SECTION Maintenance Storage Track and Suspension Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support... This will allow the track to hang freely... Elevate the front end of the machine and place blocks securely under it to remove tension from the shocks and springs... This will minimize fatigue on the front shocks and springs...

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ADULT SECTION Maintenance Transporting the Snowmobile Whenever the snowmobile is transported the following measures should be taken: 1... Turn the fuel valve off... 2... Be sure the fuel cap is installed correctly... 3... Always tie the snowmobile to the transporting unit securely using

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TROUBLESHOOTING Engine Turns Over, Fails to Start Contact your POLARIS dealer for service if you're unable to identify solutions using the following chart...

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Carburetor Model BV18 Idle RPM +/- 200 1650 Rated Operating RPM 3600 Main Jet 70 Pilot Jet 50 Jet Needle N/A Needle Jet N/A Cutaway 170 Throttle Valve Fuel Screw 1... 75 Turns; Non-adjustable Pilot Air Jet 1... 3 mm Cooling Air Cylinders 1 Ignition Timing 23 BTDC @ 3600 RPM Ignition Type Flywheel Magneto (solid state) Spark Plug/Gap NGK BR6ES/... 028" (... 70 mm) Recommended Engine Oil PS-4 or PS-4 Plus Recommended Fuel Octane Minimum 87 octane non-oxygenated or 89

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The carburetor jetting chart above is consistent with the provisions of U... S... A... federal regulation 40 CFR 1051... 115(d)(3) and is an acceptable alternative to the use of tamper-resistant features...

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Engine Lubricants 2870791 Fogging Oil (12 oz... Aerosol) 2874865 Performance Synthetic 4-Stroke (PS-4) Oil (qt... ) 2874866 Performance Synthetic 4-Stroke (PS-4) Oil (gal... ) 2876244 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (qt... ) 2876245 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (gal... )

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WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty information contained in this manual... Contact your POLARIS dealer for replacement parts, service or warranty... Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual... Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you... When contacting us about parts, service, or warranty, always provide the following information: 1... Serial number 2... Model number 3... Dealer name 4... Date of purchase 5... Details of trouble experienced 6... Length of time and conditions of operation 7... Previous correspondence Use the page provided near the front of your owners manual to record the identification numbers of your snowmobile and its engine... POLARIS Customer Service United States & Canada: 1-800-POLARIS (1-800-765-2747) French: 1-800-268-6334

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Registration At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase... Upon receipt of this registration, POLARIS will record the registration for warranty... No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage... If you have not signed the original registration and received the customer copy, please contact your dealer immediately... NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS... Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation... Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage...

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This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components; unauthorized repairs; repairs made after the warranty period expires or by an unauthorized repair center; use of the product in competition or for commercial purposes... Warranty will not apply to any product which has been damaged by abuse, accident, fire or any other casualty not determined a defect of materials or workmanship...

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THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS... THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY... POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE... THIS EXCLUSION OF CONSEQUENTAL, INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE...

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If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move... Product importation rules vary considerably from country to country... You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage... You may also be required to obtain documentation from POLARIS in order to register your product in your new country... You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle...

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WARRANTY Exported Products EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALERS AUTHORIZED LOCATION... This policy does not apply to products that have received authorization for export from POLARIS... Dealers may not give authorization for export... You should consult an authorized dealer to determine this products warranty or service coverage if you have any questions... This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealers authorized location... This policy does not apply to safety bulletins...

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WARRANTY U... S... A... EPA Emissions Limited Warranty This Emissions Limited Warranty is in addition to the POLARIS standard Limited Warranty for your vehicle... POLARIS Industries Inc... warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U... S... Environmental Protection Agency emission regulations... POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations...

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WARRANTY U... S... A... EPA Emissions Limited Warranty The exclusive remedy for breach of this Limited Warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products... THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY... POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE... THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE...

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MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced... This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile...

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DATE HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

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E Electrical Connections ... ... ... ... ... ... ... ... ... ... ... 73 Emergency Preparation... ... ... ... ... ... ... ... ... ... ... 78 Emission Control Information ... ... ... ... ... 48 Emissions Limited Warranty ... ... ... 89-90 Engine Break-In ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42 Engine Oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 61-62 Engine Starting ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45 Engine Stop Switch... ... ... ... ... ... ... ... ... ... ... ... ... ... 14 Environment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7-8 Exhaust System... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 54

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Safety Labels ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 13 Safety Symbols ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10 Signal Words ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10 Skag Replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... 71 Slider Replacement ... ... ... ... ... ... ... ... ... ... ... ... ... 68 Snow and Ice Build-Up ... ... ... ... ... ... ... ... ... ... 36 Spark Plugs ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52-53 Speed/Performance Regulation ... ... ... ... 44 Starting the Engine ... ... ... ... ... ... ... ... ... ... ... ... ... 45 Steering Adjustment ... ... ... ... ... ... ... ... ... ... ... ... 69 Steering Inspection ... ... ... ... ... ... ... ... ... ... ... ... ... 69 Steering System ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 68 Stop Switch ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14 Stopping... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18 Stopping Procedures ... ... ... ... ... ... ... ... ... ... ... ... 46 Storage ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46, 75-77

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2100 Hwy... 55, Medina, MN 55340 Part No... 9925112 Rev 01 Printed in USA

Manualsnet FAQs

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