Polaris 340, 600, 800 EDGE TOwner's Manual PDF

Pages 151
Year 2005
Language(s)
English en
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1 of 151

Summary of Content for Polaris 340, 600, 800 EDGE TOwner's Manual PDF

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cause cancer and birth defects or other reproductive harm, onto the snow on which they operate... Keep this engine properly tuned and avoid unnecessary

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Copyright 2004 Polaris Sales Inc... All information contained within this publication is based on the latest product information at the time of publication... Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication... 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...

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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...

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TABLE OF CONTENTS Introduction 5... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owners manual...

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n Follow the maintenance program outlined in this manual... Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals...

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Polaris snowmobiles are engineered to conform to these SAE standards... Our muffler systems are designed to reduce noise levels and must not be altered or removed... The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others... We do our part by manufacturing quieter machines; we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly...

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INTRODUCTION Vehicle Identification Numbers The tunnel vehicle identification number (VIN) and engine serial number are important for model identification when registering your snowmobile, when obtaining insurance, and when ordering replacement parts... In the event your snowmobile is stolen, these numbers are essential to its recovery and identification...

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

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WARNING Driving a snowmobile requires your full attention... DO NOT drink alcohol or use drugs or medications before or while driving... They will reduce your alertness and slow your reaction time... In most states and provinces, its prohibited by law to drive while intoxicated or under the influence of drugs... Polaris produces high performance snowmobiles capable of traveling at high speeds... Extra caution must be observed to ensure operator safety... Make sure your snowmobile is in excellent operating condition at all times... We strongly recommend that the operator check major and vital safety components before every ride... All Polaris snowmobiles are designed and tested to provide safe operation when used as directed... Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power... DO NOT MODIFY YOUR MACHINE... The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed... Loss of control may occur at higher speeds... Modifications may also create a safety hazard and lead to bodily injury... The warranty on your entire machine is terminated if any equipment has been added, or any modifications have been made, to increase the speed or power of the snowmobile...

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Operating a snowmobile requires skill and balance for proper control... Rider positions may vary from person to person as each becomes more skilled; but under most conditions, the proper position is to be seated with feet on the running boards, and comfortably positioned for proper throttle, brake, and steering control...

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SAFETY Operator Safety Survival Preparation For your safety, always ride in a group of other snowmobilers... Always tell someone where youre going and how long you expect to be gone... If it isnt possible to ride with others, and you must travel into remote areas, always carry survival equipment thats appropriate to the conditions you may encounter... Such equipment may include, but is not limited to: extra clothing, a sleeping bag, a flashlight, food and water, a signaling mirror, a means of building a fire, and a two-way radio or cellular telephone...

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WARNING Control becomes more difficult with two people on board... More space is required to make turns, and longer distances are needed for stopping... Make sure the passenger remains seated behind the driver, facing forward, with both feet placed firmly on the running boards... Slow down and avoid jumping your snowmobile...

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Always be alert and pay attention to the trail ahead... Multiplying speed (MPH) by 1... 5 will equal the approximate number of feet per second your machine travels... If your speed is 40 MPH, your machine is traveling about 60 feet per second... If you look back for only two seconds, your machine will travel about 120 feet... If your speed is 60 MPH, your machine will travel about 180 feet in two seconds...

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Variances in snow depth and/or water currents may result in uneven ice thickness... Always check with local residents or authorities for general information on conditions when traveling on lakes and streams that are strange to you... Before riding your machine on a frozen body of water, be sure the ice is thick enough to support the machine and its operator, as well as the force created by a moving vehicle... You may drown if you and the snowmobile break through the ice...

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You dont have to be snowmobiling on a slope for an avalance to occur... Be aware that all of the snow is connected... You may be riding on a flat slope or snow covered road, but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you... Always be aware of snow conditions above you as you travel in mountainous terrain...

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Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering... If difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage... Snow screens and bib kits are available through your dealer to help reduce snow and ice build-up...

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If youre unable to continue up a hill, turn the machine downhill before it loses momentum... If this isnt possible, spin the track just enough to dig in to prevent it from rolling back down the hill... Stop the engine and set the parking brake (if equipped)... Keeping away from the downhill side of the machine, pull the rear of the snowmobile around and point the front end and skis downhill... Remount the machine, restart the engine, release the parking brake, and descend the hill carefully...

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WARNING When driving on long downhill stretches, pump the brakes... Riding the brakes may cause the brake system to overheat, which may result in brake failure... Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system... This condition may lead to a sudden loss of brakes and/or fire and may result in serious injury or death...

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Cold Weather Drive-Away Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from ice and snow before attempting to drive... Apply the throttle with enough authority to put the machine into motion, but always operate within safety limits and, on 2-Up machines, with respect for a passenger... See Starting a Cold Engine on page 58...

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CAUTION When operating on icy surfaces or hard-packed snow, avoid overheating the slide rail and track... Lack of lubrication and cooling will cause overheating of the slide rail and track, resulting in premature wear and failure... If frequently operating in low cooling conditions, see your dealer for an optional wheel kit that will reduce the wear from overheating...

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SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly... If youre new to snowmobiling, acquaint yourself with the machine and with what it will and wont do under various conditions... Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers...

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SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding...

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SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protection... Read and follow the instructions of the decals and other warnings on the snowmobile carefully... If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile...

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Cargo Carrier Warnings Machines with a cargo carrier have a cargo weight decal at the rear of the snowmobile... The decal specifies the maximum recommended weight capacity for the carrier... Never exceed the maximum recommended weight capacity for your machine...

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SAFETY Safety Decals and Locations Standard Reverse Warning The Polaris WideTrak snowmobile is equipped with standard reverse... The reverse warning decal is located above the instrument housing...

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SAFETY Safety Decals and Locations Electronic Reverse Warning Polaris snowmobiles equipped with electronic reverse will have the electronic reverse warning decal...

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SAFETY Safety Decals and Locations Operation Warning Operation warning decals are present on the console of all Polaris snowmobiles, in both French and English...

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SAFETY Safety Decals and Locations Operation Warning

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FEATURES Some Polaris snowmobiles are equipped with special features... Operating controls and special feature controls are illustrated on this page... Not all models come with all special features... Refer to your Owners Manual Supplement for the features on your machine...

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11... Snow Flap 12... Passenger Grab Handle 13... Track 14... Suspension 15... Trailing Arm 16... Nosepan 17... Front Bumper 18... Skis 19... Grab Handle Heater Switch 20... Passenger Hand Hold Strap

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Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions... We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference... The machine should be methodically tested, one change at a time, under the same conditions (trail and snow conditions, vehicle speed, riding position, etc... ) after each adjustment until the best ride is achieved...

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For the best ride, the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming... To determine if your machine is using full travel, push the jounce bumper down on the shock rod until it contacts the body and test ride the machine... The bumper will move up on the rod in relation to the amount of travel that was used during the ride... If the travel is full, the bumper will be seated at the top of the rod...

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Indy Select Shock The factory setting for this shock is the softest position, with the adjusting screw all the way out (counterclockwise)... If bottoming occurs, the Indy Select feature should be used to achieve the desired ride... The shocks have a wide range of adjustment capability... By turning the screw clockwise, the compression of the shock increases, stiffening the ride... When adjusting these shocks, we recommend that you turn the screw only 1/4 turn at a time, then test ride... Always adjust both shocks equally...

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Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension... Never exceed one inch of preload beyond the factory settings, and ensure that both sides are adjusted the same... When decreasing preload, make sure at least two turns of preload are holding the spring between the retainer on top of the shock and the threaded spring preload adjuster nut on the shock body...

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WARNING Changing shock valving on RydeFX and RydeFX SOLO shocks requires special tools and a sound knowledge of mechanical theory, tool use, and shop procedures to perform the work safely and correctly... Shocks contain high-pressure nitrogen gas... Use extreme caution when handling high-pressure service equipment... We recommend that this work be performed by a Polaris dealer...

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Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions... However, all suspension designs and adjustments involve a compromise, or trade-off... For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail... A suspension set up for trail riding would bottom out harshly on a snow-cross course...

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If the rear suspension rides in less than three inches or more than five inches with the torsion spring preload cams at their maximum range of adjustment, optional torsion springs (softer or stiffer, respectively) may be required... This is only an initial set-up, and final spring preload may vary based on rider preference and riding conditions...

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The Indy Select rear shock allows for adjustments to the compression valving... Locate the adjustment screw (A) near the base of the shock... In half-turn increments, turn the screw clockwise to increase compression valving and stiffen the ride, or counterclockwise to reduce compression and soften the ride... There are approximately three full turns of adjustment available...

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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... There are two types of rear suspension coupling...

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Adjusting the RRSS either allows more weight to transfer to the rear for more traction, or allows less weight to transfer to the rear, resulting in improved cornering performance... An adjustment dot is located on the RRSS... This dot is on the longest end of the scissor stop...

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Weight Transfer During Acceleration Rear Rear Scissor Stop (RRSS) The preferred method for controlling weight transfer during acceleration of the EDGE rear suspension is by adjusting the RRSS... The RRSS is located in the best overall trail riding position when delivered from the factory...

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THE PERFECT FIT Edge Touring Suspension (ETS) Adjustments Torsion Springs Two torsion springs are used on the rear arm of the ETS... Preload adjustments can be made by turning the rectangular adjusters with a spark plug wrench... The firm torsion spring should be used if frequent bottoming is encountered during two up riding on rough trails... The soft torsion spring should be used for frequent one up riding on smooth trails... For soft tension, position the long end of the cam to the front (A)... For firm tension, position the long end of the cam up (B)...

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Front Arm Mounting Holes There are also two front arm mounting holes in the slide rail that can adjust ski pressure... The lower hole (C) increases ski pressure while the upper hole (D) decreases ski pressure...

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4... A fail-safe mode has been programmed into the controller to protect the electronics and to notify the operator of a system malfunction... If the module cannot adjust the suspension after one of the switches has been pressed (most likely due to an obstruction or heavy ice buildup), the controller will enter a failure mode, which is indicated by the gauge needle moving rapidly between soft and firm... This mode will continue indefinitely and is reset when the engine is turned off and restarted... If this mode is encountered, we recommend that the operator turn off the engine and inspect the unit for any obstruction or ice buildup on the shock or module...

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THE PERFECT FIT ETS ACE Adjustments ETS ACE Settings IMPORTANT NOTES: The time to move one position can take up to 12 seconds depending on the rear shock loads...

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running board... The difference between the two readings should be approximately 1 1/2 (3... 8 cm)... If the difference is greater than 1 1/2, the rear spring should be adjusted equally on both sides until the desired 1 1/2 drop is obtained...

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3... Adjust the handlebar to the desired height... Be sure handlebars, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right...

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THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile... From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable... See your dealer for a list of accessories...

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A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain... The addition of carbide skags is recommended with studded tracks to help maintain proper vehicle steering and control... Similarly, if your machine is equipped with carbide skags or youre adding them, it may be necessary to add track studs to maintain proper vehicle control... Proper balance must be maintained between the number of studs and the length of carbide on skags... The more studs used, the longer the carbide on the skags should be... See your dealers track studding chart for recommended studding and skags...

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CAUTION If traction products are added to the track, wear strips must be installed in the tunnel to avoid excessive wear... Never add shims to the wear strip... Track damage will result because of lack of clearance between upper carrier wheels and track... Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tunnel...

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THE PERFECT FIT Accessories Wear Strips To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used... Several wear strips are available... See your dealer for more information...

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

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Make sure the throttle lever compresses evenly and smoothly... The lever should immediately return to the idle position without binding or hesitation... If the throttle does not function smoothly, or if you discover excessive lever freeplay, DO NOT start the engine... Have the throttle serviced immediately...

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Lever Feel A hydraulic system multiplies the force of your hand squeezing the brake lever... Proper operation depends on an adequate supply of air and moisture-free hydraulic brake fluid in the system... If the brake lever feels spongy when squeezed, check the level and condition of the fluid... Also check for the presence of air in the fluid system... Refer to page 105 for more information, or see your dealer for service...

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If the brake handle is squeezed tightly enough, the lock will move freely into place... Do not force the lock or it may break... To release the lock, squeeze the brake handle until the lever returns to the unlock position... The park brake light on the console will light up when the park brake lever lock is set and the engine is running... It will also be lit when the service brake is in use... If the park brake light does not come on when the park brake or service brake is in use, have it serviced by your dealer... 1... Brake Handle 2... Park Brake Lever Lock (not

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Use of traction products such as studs increases the possibility of track damage and/or failure... Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods, break track edges, and cause other track damage... Examples of marginal lubrication would include frozen bodies of water without snow cover, icy trails, and no-snow conditions...

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n Check Surroundings to Verify Clear Operating Area: Make sure you have a clear area all around your snowmobile, including an area clear of bystanders... Theres always the possibility of some sideways vehicle movement, of applying a little more throttle than intended, or of debris being thrown by the track... If the surrounding area is clear you before you start, you can devote your full attention to operating the snowmobile...

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WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation... Never start your snowmobile without checking all components to be sure of proper operation... See Check Before Starting the Engine beginning on page 53...

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NOTE: WideTrak models may also be warmed up with the transmission in neutral and the brake engaged... This will allow the engine to warm without engaging the drive system... Dont leave the machine in this position for more than five minutes... Engine RPM must be at idle before shifting the transmission...

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CAUTION Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts... Do not operate at full throttle or high speeds for extended periods during the first three hours of use... Vary the throttle openings and machine speeds to reduce friction on all close-fitting machined parts, allowing them to break in slowly without damage... Use of any lubricants other than those recommended by Polaris may cause serious engine damage... We recommend the use of Polaris lubricants for your vehicle... Drive with extra caution during the break-in period... Perform regular checks on fluid levels, lines, and all other important areas of the machine...

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Oil Recommendations The only source of engine lubrication for your engine comes from lubrication added to the fuel and oil injection systems... We highly recommend the use of only Polaris products... Were continuously testing lubricants and provide the highest performance products available for your snowmobiles engine... Refer to the table below to determine the recommended oils for use in your Polaris snowmobile...

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

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WARNING Gasoline is highly flammable and explosive under certain conditions... S Always exercise extreme caution whenever handling gasoline... S Always refuel with the engine stopped, and outdoors or in a well ventilated area... S Do not overfill the tank... Do not fill the tank neck... S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored... S If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing... S Never start the engine or let it run in an enclosed area... Engine exhaust fumes are poisonous and can cause loss of conscious- ness or death in a short time... S Turn the fuel valve off whenever the snowmobile is stored or parked...

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If youre uncertain about the quality or octane rating of the fuel you use, turn your key switch to ON/REG... The Premium Fuel light will go out... This setting will adjust the timing of your engine to run on fuels with 87 octane or higher... Polaris does not recommend using fuel with lower than 87 octane... Running your machine on ON/REG will help protect your engine from damage caused by low octane fuels...

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Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer... Add one to two ounces per gallon (8-16 milliliters per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures... Never use deicers or additives containing methanol... See page 132 for the part numbers of Polaris products...

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Never mix brands of oil... Serious chemical reactions can cause injection system blockage, resulting in serious engine damage... They may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates... All Polaris oils are compatible with each other...

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NOTE: Always ensure that the correct jets are installed in the machine for your geographical area... Use care when jetting down in warm weather... As the weather turns colder you must re-jet upward to prevent engine damage... When selecting the proper main jet, always use the lowest elevation and temperature likely to be encountered...

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WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident... If the throttle safety switch does not shut off the engine during a carburetor/throttle system malfunction, immediately push down the engine stop switch... Do not start the engine again until the malfunction has been corrected by your dealer...

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If an emergency exists and its necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from the wire harness... When these switches are disconnected, the ignition key switch must be used to shut off the engine... DO NOT continue to operate the machine with the throttle safety switch disconnected... Return the machine to an authorized Polaris dealer for service as soon as possible...

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OPERATION Passenger Seat The passenger seat features an adjustable lumbar support... To adjust for rider comfort, rotate the lumbar adjustment knob (A)...

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WARNING Excessive or repetitive use of brakes for high speed stops will cause an overheated brake system... This overheated condition could cause sudden loss of brakes and/or fire, resulting in serious injury or death... When traveling on long downhill stretches, pump the brakes... Riding the brakes may cause the brake system to overheat and result in brake failure...

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OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use... Machines equipped with electric start have a recoil for emergency starting... On non-electric start models, if the recoil starter system fails, an emergency start strap is provided in the kit...

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Sometimes the drive belt will drag in the drive clutch, causing slight tension in the transmission and making it hard to shift... Shutting the engine off will remove this tension and ease shifting... This should only happen during the break-in of a new belt or when the drive/driven clutch center distance is too long... If this is the case, belt tension adjustments should be made by your dealer...

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Misfire Mode (Fan Cooled Models) Air flow on fan cooled models is limited during reverse operation due to reverse operation of the fan... After 45 seconds in reverse, the engine will default into the misfire mode to prevent engine overheating... Disengaging Reverse Push the yellow reverse button on the left-hand control for one second and release... The engine will slow and and begin to rotate forward... The light on the instrument panel will shut off... Make sure the area around your vehicle is clear and apply throttle slowly until youre sure the machine is in forward gear... Altitude Settings At altitudes above 6000 feet, engines require different ignition settings to improve the success of the reverse system... A new setting is stored in memory until changed, whether the machine is running or not... To set for a higher altitude, start the engine and press the reverse button until the light on the instrument panel flashes rapidly, then release... To set the reverse for lower elevations, continue pressing the button until the indicator light blinks slowly...

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WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in serious injury or death... DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a rope... Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used... If passengers are to be towed on a toboggan or sled, make sure the pole is at least four feet (1... 2 meters) long to prevent any possibility of contact between the snowmobiles track and a person riding in the towed object... Braking distances increase when towing loads... Slow down to maintain control of the snowmobile...

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The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km), and 1000 miles (1600 km)... These inspections should be performed by a qualified service technician... For continued optimum performance and component life, continue maintenance checks at 1000 mile (1600 km) intervals...

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MAINTENANCE Periodic Maintenance Interval Table 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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I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate

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I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate

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I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate

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

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MAINTENANCE Maintenance Log Additional Services Performed

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S Lubricate both of the front ski pivots at the fittings as shown... S Grease the jackshaft and driveshaft clutch side bearings... S Use an aerosol lubricant on the steering post support bracket... S Grease the center steering arms... S Grease the steering post lower pivot... S Grease the rear suspension pivot shafts (raise the rear of unit)...

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MAINTENANCE Lubrication The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year... Lack of lubrication will adversely affect your ride and the life of the suspension... For detailed information about suspension lubrication and adjustments, see your Polaris dealer...

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MAINTENANCE Lubrication Jackshaft Bearing Greasing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting... Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps)... Push the clutch back onto the shaft and replace the clutch retaining bolt... Torque to 18 ft... lbs... (24... 4 Nm)...

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Choke and Cable Lubricate the choke slide (2) and cables lightly with oil or grease... Before turning the engine off, operate the choke intermittently to draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen...

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To check the oil level, place the machine on a level surface... The oil level should be between the safe marks on the dipstick (A)... See your Polaris dealer for the recommended oil for your machine... Do not overfill...

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To check the oil level, place the machine on a level surface... The oil level should be between the safe marks on the dipstick (A)... Add Polaris chaincase oil (PN 2871280) through the dipstick opening... Do not overfill... See page 132 for the part numbers of Polaris products...

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In selecting a spark plug heat range for production, a manufacturer assumes that the engine will be operated under extreme heavy duty conditions and selects a spark plug that will protect the engine from internal damage if the purchaser actually does operate the engine in this manner... This selection could cause the customer who normally operates the engine under medium or light duty to have spark plug failure... Refer to your Owners Manual Supplement for the specific spark plug to be used in your machine...

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2... Wet Fouled The wet fouled insulator tip is black... A damp oil film covers the firing end... There may be a carbon layer over the entire nose... Generally, the electrodes are not worn... General causes of fouling are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments...

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MAINTENANCE General Maintenance Intake Filter The intake foam filter limits snow ingestion into the intake system... When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow...

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Water Pump Belt Inspection Polaris Liberty 700 and 800 engines require inspection of the water pump belt at 1500 miles (2400 km)... Inspect belt width (A) and condition... Replace if cracked or worn past the width service limit (... 250 / 6... 35mm)... New belt width is approximately ... 345 (8... 75 mm)... See your Polaris dealer if the belt needs to be replaced...

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MAINTENANCE General Maintenance Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor... The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination...

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Edge models use an oil filter thats built into the oil sending unit located in the bottom of the oil tank... After changing the oil filter, bleed the oil injection system of all trapped air... See your dealer for instructions, or have your dealer perform the filter change and bleeding operation for you...

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MAINTENANCE General Maintenance General Carburetor Information The number stamped in the end of the main jet indicates the jet size... The jet installed at the time of manufacture is not necessarily correct for your elevation... Its your dealers responsibility to make sure the correct main jet is installed...

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MAINTENANCE General Maintenance Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles (1600 km)... 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 grommets...

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MAINTENANCE General Maintenance Coolant Mixture The coolant supplied in the system is a 50/50 mixture of ethylene-glycol and distilled water... This mixture provides protection against freezing at temperatures to -34 F (-37 C)... If greater protection is required, the percentage of antifreeze to water may be increased... Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use... Do not dilute with water... Never exceed a 60% antifreeze/40% water mixture... Contact you dealer if greater protection is required...

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MAINTENANCE General Maintenance Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh mixture of antifreeze and distilled water should be added... This service must be done when the engine is cold... Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile...

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CAUTION If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result... Most cooling systems are equipped with a filter that should be periodically inspected or replaced...

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1... Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side... Lock the brake lever lock, or have an assistant hold the brake lever firmly...

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WARNING Brake failure during operation can result in serious injury or death... Properly functioning brakes are vital to your safety... Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive... Always replace brake pads when the brake pad material becomes thinner than the backing plate (approximately 1/16)...

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Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as described on page 102, the machine should be returned to an authorized Polaris dealer for inspection and adjustment...

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WARNING After opening a bottle of brake fluid, always discard any unused portion... Never store or use a partial bottle... Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air... The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury...

Page 108

WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death... Never operate the vehicle with a spongy-feeling brake lever...

Page 109

Frequently inspect the brake lever reserve (A), which is the clearance between the lever and the brake block... To inspect, firmly depress the brake lever and measure the distance between the lever and the brake block... This distance should be no more than 3/4 (1... 9 cm)... If brake lever reserve exceeds this amount, see your dealer for service...

Page 110

4... Observe the headlight aim... The most intense part of the headlight beam should be aimed 2 (5... 1 cm) below the mark placed on the wall in step 2...

Page 111

Installing the Bulb 1... Hold bulb by metal base and install into wire harness... 2... Insert bulb into housing... 3... Carefully flip spring back into housing placing it around wire

Page 112

1... Remove the rear storage cover (A) if equipped... 2... Depending on your model, remove the screws (B) securing either

Page 113

The drive belt is a very important part of the drive system... Belt width and length must match the center distance of the clutches and sheave width of the drive clutch... For this reason, Polaris recommends that only O... E... M... belts be used... Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor performance... See your dealer for service and adjustments...

Page 114

MAINTENANCE General Maintenance n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare... Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness... Replace the belt if any of these conditions exist...

Page 115

NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them... If required, separate the sheaves as outlined in the belt removal procedures...

Page 116

Clutch Center Distance See your Owners Manual Supplement for recommended center distance for your machine... If adjustment is necessary, see your dealer... Due to tolerances in belt length, it may be necessary for your dealer to make minor adjustments in the driven clutch to achieve correct belt tension...

Page 117

MAINTENANCE General Maintenance Torque Stop If your snowmobile is equipped with an engine torque stop (1), periodically check torque stop clearance... With clutches in proper alignment, the torque stop clearance should be a minimum of ... 010 to a maximum of ... 030 from the engine case (2)... Adjust if necessary, and lock the jam nut...

Page 118

MAINTENANCE General Maintenance Tool Kit A tool kit is included with each machine for emergency and routine maintenance... Your tool kit will contain only the tools applicable to your model...

Page 119

MAINTENANCE General Maintenance Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer... His experienced and trained service technician will keep your machine in peak operating condition...

Page 120

WARNING Operating with insufficient lubrication between the Hi-fax and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death... Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication...

Page 121

3... Place the recommended weight or downward pressure on the track at the specified distance ahead of the center of the rear idler wheel to slightly preload the track (see chart on page 119)... Measure at the point where the weight is hanging...

Page 122

3... Inspect track alignment by looking through the track window to make sure the rails (A) are evenly spaced on each side... If the track runs to the left, loosen left locknut and tighten the left adjusting bolt... If the track runs to the right, loosen right locknut and tighten the right adjusting bolt...

Page 123

With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt... The measurement between the skis at point X should be 1/8 to 1/4 greater than the measurement at point Y...

Page 125

MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check fasteners and tighten if necessary... Specific fasteners that should be checked are marked with a in the following illustrations...

Page 126

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

Page 127

MAINTENANCE Suspension Maintenance n Hi-Fax Wear Check Hi-fax wear by measuring the thickness at several points along the rail (A)... Replace Hi-fax when a thickness of 7/16 is reached (3/8 on WideTrak models)... See your dealer for Hi-fax replacement...

Page 128

Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts... Wipe down remaining surfaces with a damp cloth... Clean and touch up with paint any rusted or previously painted surfaces... Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors (grease, oil or paint)...

Page 129

Clutch and Drive System Remove the drive belt and store in a cool dry location... Lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant... See page 132 for part numbers... Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual... See your dealer...

Page 130

Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors... Lubricate or pack connector blocks with dielectric grease and re-connect... See page 132 for the part numbers of Polaris products...

Page 131

MAINTENANCE Extended Storage Track and Suspension Moderate track tension should be maintained during summer storage... The machine should be supported off the ground to allow the track to hang freely... See illustration...

Page 132

WARNING Battery electrolyte is poisonous... It contains acid! Serious burns can result from contact with the skin, eyes, or clothing... If contact occurs, seek immediate medical attention... KEEP OUT OF REACH OF CHILDREN... EXTERNAL: Flush with water... INTERNAL: Drink large quantities of water or milk... Call physician immediately... EYES: Flush with water for 15 minutes and get prompt medical attention... Batteries produce explosive gases... Keep sparks, open flames, cigarettes, etc... away... Ventilate when charging or using in closed space... Always shield eyes when working near batteries...

Page 133

MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion... When cleaning is necessary, remove the corrosion with a stiff wire brush... Wash terminals and connections with a solution of one tablespoon baking soda and one cup water... Rinse well with tap water and dry with clean shop towels... Coat the terminals with dielectric grease or petroleum jelly...

Page 134

WARNING Batteries contain gases that can explode... If the battery vent tube is pinched or kinked, battery gases could accumulate... Whenever removing or installing the battery, disconnect the negative (black) cable first and reinstall the negative cable last to avoid the possibility of explosion... Battery electrolyte contains acid... Avoid skin contact with electrolyte as severe burns may result...

Page 135

2872347 Premium Gold Synthetic 2-Cycle Engine Oil (2... 5 gal... )

Page 136

TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise...

Page 137

Hydrostatic lock Fuel may have entered crankcase while ve- hicle was standing or being transported... SEE YOUR DEALER to correct cause... Drain plug(s) are located on lower crank- case for emergency draining...

Page 138

Ice in fuel line, filter, or pump... On the standard Polaris carburetor, the choke will not function with the throttle depressed... See second item under Probable Cause of Engine continually backfires...

Page 139

- Make sure skis are aligned properly... - Make sure spindles and all steering components are free turning... - Make sure skags are straight on skis... - Check hi-fax and replace if worn... - Reduce ski pressure: SIncrease front track spring preload... SReduce IFS spring preload by adjusting threaded collar... SReduce rear torsion spring preload...

Page 140

- Adjust RCA forward (see setup decal under hood)... - Adjust coil over spring on front track shock to increase preload - 1 maximum preload... - Adjust torsion spring blocks to highest position... - Increase front track compression damping by turning screw clockwise (factory position full soft)... - Replace front track spring with optional spring...

Page 141

Skis may gouge into trailers and prevent the drivetrain from spinning properly... Use enough speed to drive the machine completely onto the trailer... Push and pull it to finish loading if necessary...

Page 142

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:

Page 143

Limitations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmanship... The warranty does not cover accidental damage, normal wear and tear, abuse or improper handling... The warranty also does not cover any snowmobile that has been structurally altered, neglected, improperly maintained, used for racing or used for purposes other than for which it was manufactured... The warranty does not cover any damages that oc- cur during trailer transit or as a result of unauthorized service or parts... In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or punc- turing of upholstery material, corrosion or defects in parts, components or the snowmo- bile due to fire, explosions or any other cause beyond Polaris control...

Page 144

WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM- PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU- LAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD... POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR- RANTIES 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 inconsistent with controlling state law...

Page 145

This warranty also excludes failures resulting from improper lubrication; improper en- gine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjust- ment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermar- ket components resulting in failure; 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 dam- aged by abuse, accident, fire or any other casualty not determined a defect of materials or workmanship...

Page 146

WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion... The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transferable 120 days after the original purchase date, free of charge, through any Polaris snowmobile dealer... Coverage on Snow Check units is automatic... Although you do not receive a warranty card, your dealership should have printed a copy of the warranty registration form... This form is your proof of warranty...

Page 147

How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer... If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle... Outside the Country where your vehicle was purchased: If you are traveling temporarily outside the country where your vehicle was purchased, you should take your vehicle to an authorized Polaris dealer... You must show the dealer photo identification from the country of the selling dealers authorized location as proof of residence... Upon residence verification, the servicing dealer will be authorized to per- form the warranty repair... If You Move: If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move... Vehicles importation rules vary considerably from country to country... You may be required to present docu- mentation of your move to Polaris Industries in order to continue your warranty cover- age... You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country... If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied...

Page 148

FEATURES Detonation Elimination Technology (D... E... T... ) (800 Touring only) Some Polaris snowmobiles are equipped with a detonation sensor that monitors the engine and responds to detonation by automatically reducing the engine timing... When activated, the DETONATION FLASH indicator (A) will flash in the lower right-hand area of the tachometer... The activated sensor reduces engine detonation by retarding the ignition timing... This results in decreased engine RPM and performance...

Page 149

C Carburetion 67... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Carburetor Adjustments 96... ... ... ... ... ... ... ... ... ... ... ... Carburetor Information 96... ... ... ... ... ... ... ... ... ... ... ... Cargo Carrier 24... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Cargo Overload 12... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Chain Tension 115... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Chaincase Oil Level 89... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Choke and Cable 87... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Cleaning and Preservation 125... ... ... ... ... ... ... ... ... Clutch Alignment 110... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clutch and Drive System 126... ... ... ... ... ... ... ... ... ... Clutch Center Distance 113... ... ... ... ... ... ... ... ... ... ... ... Clutch Cover 23... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clutch Guard 18... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clutch System 110... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clutch, Standard 113... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clutch, TEAM 113... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Clutches 19... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Coil Springs, Edge 136 39... ... ... ... ... ... ... ... ... ... ... ... ... Cold Weather Drive-Away 19... ... ... ... ... ... ... ... ... ... Controls and Linkage 126... ... ... ... ... ... ... ... ... ... ... ... ... Coolant Level 98... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Coolant Mixture 98... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Cooling 97... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Coupler Greasing 86... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

Page 150

R Rear Spring Settings, WideTrak 46... ... ... ... ... ... Rear Spring Tension, Edge 136 38... ... ... ... ... ... Rear To Front Coupling, Edge 136 40... ... ... ... Recommended Maintenance Program 76... Reverse 25-26... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Reverse Maintenance 114... ... ... ... ... ... ... ... ... ... ... ... ... Reverse Operation 73... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Reverse, Electronic 74... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Reverse, Mechanical 73... ... ... ... ... ... ... ... ... ... ... ... ... ... Ride Control Adjuster, ETS 43... ... ... ... ... ... ... ... ... Rider Capacities 12... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Riding Apparel 11... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Riding Position 10... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... RRSS, Edge 136 40-41... ... ... ... ... ... ... ... ... ... ... ... ... ... ... RydeFX SOLO Shock 33... ... ... ... ... ... ... ... ... ... ... ... ... ...

Page 151

Shock, Indy Select Rear, Edge 136 38... ... ... Signal words 8... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Skag Replacement 123... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Ski Alignment 120... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Ski Skags 123... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Slide Rail and Track Cooling 63... ... ... ... ... ... ... ... Spark Plugs 90-91... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Spring Preload, Edge 136 37... ... ... ... ... ... ... ... ... ... ... Spring Tension, Rear, Edge 136 38... ... ... ... ... ... Start the Engine and Check 57... ... ... ... ... ... ... ... ... Starting 72... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Starting a Cold Engine 58-59... ... ... ... ... ... ... ... ... ... Starting a Warm Engine 59... ... ... ... ... ... ... ... ... ... ... ... Starting the Engine 58... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Steering Adjustment 122... ... ... ... ... ... ... ... ... ... ... ... ... ... Steering Inspection 122... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Steering System 56, 120-123... ... ... ... ... ... ... ... ... ... Stopping 71... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Storage 75, 125-128... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Survival Preparation 11... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Suspension 128... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Suspension Coupling, Edge 136 39... ... ... ... ... ... Suspension Maintenance 124-125... ... ... ... ... ... Suspension Performance Tips 36... ... ... ... ... ... ... Suspension Troubleshooting 136-137... ... ... Suspension, Front 31-35... ... ... ... ... ... ... ... ... ... ... ... ... ... Suspension, Rear 36... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Suspension, Rear, Edge 136 37-41... ... ... ... ... ... Suspension, Rear, Edge Touring 42-43... ... Suspension, Rear, ETS ACE 44-45... ... ... ... ... ... Suspension, Rear, WideTrak 46... ... ... ... ... ... ... ... Symbols 8... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

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