Instruction/ maintenance manual of the product Trail Touring Polaris
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Pantone 280 CVC For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No.
W ARNING Read, understand, and follow all of the in structions and sa fe ty precau tions in this manual a nd on al l product lab els. F ailure to follow the safety precautions could result in serious injury or death.
1 WELCOME Thank you for purch asing a Polaris vehicle, and welcome to our world- wide family of Polaris enthusiasts. Be sure to visit us onli ne at www .polarisindustries.com for the la test news, new product introduc- tions, upcoming events, car eer opportunities and more.
2 POLARIS and POLARIS THE W A Y OU T are regi stered tradem arks of Polaris Indus- tries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication.
3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 This section contains helpful info rmatio n for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner's manual.
4 INTRODUCTION V ehicle Identification Numbers Record your sno wmobile's identificati on numbers and k ey number in the spaces provided. Remove the spare key and store it in a safe place.
5 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourag e governmen ts to adop t rigorous safety training pro- grams that encourage protection of ou r environment, including wildl ife and vegetation.
6 SAFETY Operator Safety The following signal words and symbol s appear througho ut this manual and on your veh icle. Y our safety is involved when these words and sym- bols are used.
7 SAFETY Operator Safety Follow the recommend ed maintenance prog ram beginning on page 70 of this manual to ensure that all critical components on the sn owmobile are thoroughly i nspected by your d ealer at specific mileage intervals. Driving a snowmobi le requires your ful l attention.
8 SAFETY Operator Safety S t ay Clear of T rack Y our snowmobile is propelled by a rev o lving track that must be partially exposed for proper operation. W ARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remai n properly seated to stay clear of the track.
9 SAFETY Operator Safety Riding App arel Be prepared, be warm an d be com- fortable when riding. Be aware of the weather forecast, espec ially the wind- chill, and dress accordingly . See the chart on page 21. W ARNING! A void wearing lo ose clothing or long scarves, which can become entangled in moving part s and cause serious injury .
10 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmo biles.
11 SAFETY Operator Safety Disabled Operators Safe operation of th is rider -active vehi cle requires good judgement and physical skills. Operators with cognitiv e or physical disabilities have an increased risk of loss of control, wh ich could result in serious injury or death.
12 SAFETY Excessive S peed Always observe a ll laws governing sn owmobile operation a nd speed limits. Always be alert and pay atten tion to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the ap proximate number of feet per sec- ond your machine travels.
13 SAFETY Operator Safety Driver A wareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snow mobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts.
14 SAFETY Operator Safety A valanches Snowmobilers should always be p roperly trained and equipped before traveling in mountainous terrain: • T ake an avalan che cl ass • T ravel with experienced people • T ravel on designated trails • Make sure each pers on is equipped with a shovel, probe and avalanche beacon.
15 SAFETY Operator Safety Ice and Snow Build-up Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If dif ficulty is encountered, remo ve ice and snow build -up that may be obstructing the steering linkage.
16 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weig ht to the rear of the machine and reduce your speed to a minimum. Appl y just enough throttle to keep the clutch engage d, allowing the engine 's compres sion to help slow the machine and keep it fro m rolling freely downhill.
17 SAFETY Operator Safety Driving in Hilly T errain W ARNING! Climbing a hill or crossing the face of a slope may result in loss of balance and machin e roll-over , causing se ri ous i njury or deat h. Use caution and good judgement when driv ing in hilly terrain.
18 SAFETY Operator Safety Clutch Guard Do not operate the engine with the clutch guard r emoved. The clutch g uard is designed to pro tect the operator from metal parts if the clutch sh ould fail. Althou gh th e ch ance of failure is extremely remote, don't defeat the purpose of the safety guard by removing it.
19 SAFETY Operator Safety Inadequate Snow Conditions Moveable hood closures are includ ed on some Polaris snowmobiles. They are normally left open and are located on the front up per and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20 _ F), Polaris recommends closing the up per hood closure.
20 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the most docile condi- tions may become dangerous if operators drive improperly . If you're new to snowmobiling, acquaint your self with the machine and with what it will and won't do under va rious conditions.
21 SAFETY Operator Safety Windchill/T emperature Chart s The following information is provided to help you determine when tem- peratures be come da ngerous for riding.
22 SAFETY Safety Decals and Locations W arning decals have been placed on the snowmobile for your protec- tion. Read and follow the instructions of the deca ls and other warnings on the snowmobile carefully .
23 SAFETY Safety Decals and Locations T rack W arning The track warning decal is on the rear of the tunnel: W ARNING St ay clear of track . Do not sit on seat back. Entanglement with the track or a fall from seat back can result in severe injury or death.
24 SAFETY Safety Decals and Locations Electronic Reverse W arning Polaris snowmobiles equipped with electronic reverse have a reverse warning decal on the lower dash: W ARNING Reverse operation, even at low speeds, can cause loss of con- trol resulting in serious injury or death.
25 SAFETY Safety Decals and Locations Operation W arning The operation warnin g decal is located on the console: W ARNING • T o avo id serious in jury or death, read and under stand all warnings and the Ow ner's Manual be fore oper ation. If manual is missing, con- t a ct a Polaris dealer for a rep lacement.
26 FEA TURES Some Polaris snowmobiles are equipp ed with special feature s. Operat- ing controls and special feature cont rols are illustrated on this page. Not all models come with all special featur es. See your Owner's Man ual Supplement. 1. Fuel Filler Cap 2.
27 FEA TURES 1. Front Bumper (do not use for pulling or dragging the snowmobile) 2. Hood 3. Headlight 4. Windshield 5. Handleba r 6. Operator Seat 7. Passenger Grab Handle 8. Passenger Seat 9. Passenger Backrest 10. Suspension 11 . T r a c k 12. T railing Arm 13.
28 FEA TURES Backrest The backrest is adjustable for either operator or passenger use. 1. Loosen the upper adjustment knobs to rais e or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest forward for operator use or rearward for passenger use.
29 THE PERFECT FIT Front Suspension Adjustment s Independent Front Suspension (IFS) Break in the suspension for about 150 miles (24 0 km) before making any fine-tuning adju stments. Settings will vary from rider to rider , depending on rider weight, vehicle speed, riding style, and trail cond itions.
30 THE PERFECT FIT Front Suspension Adjustment s W ARNING! Improper ski alignment o r adjust ment may cause loss of steering control, resulting in serious inj ury or death. Always verify ski alignment before making adjustments to the IFS. See p age 100 to check alignment.
31 THE PERFECT FIT Front Suspension Adjustment s S pring Preload Increasing spring preload will increase ski-to-ground pressure. Decrea sing spring preload will decrease ski-to- ground pressu re. When adjusti ng, be sure the springs on both the left and right sides of the machine are at the same adjustment.
32 THE PERFECT FIT Rear Suspension Adjustment s Rider weight, riding style, trail co nditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions.
33 THE PERFECT FIT Rear Suspension Adjustment s Suspension Performance T ip s • Rider weight usually determines th e position a t which the spring pre- load should be set. However , this ma y vary with riding style. W ith a little experimentation, each rider can find a preferred setup.
34 THE PERFECT FIT EDGE 136 Rear Suspension Adjustment s Initial S pring Preload Setting (Sag Method) T o set up the EDGE rear suspension torsion spring prel oad, measure the distance between the ground and rear bumper . This is measurement X. T ake the first measurement with no rider and with the rear suspension at full extension.
35 THE PERFECT FIT EDGE 136 Rear Susp ension Adjustment s Rear S pring T ension T o adjust rear torsion spring tension, rotate the three-position cam usi ng the engin e spark plug tool . Different rate torsion springs are available if a firmer ride is desired.
36 THE PERFECT FIT EDGE 136 Rear Suspension Adjustment s Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shoc k, which allows for adjustments to the compression valving. Locate the adjust- ment screw near the base of the shock.
37 THE PERFECT FIT EDGE 136 Rear Susp ension Adjustment s Optional T orsion Springs Different rate torsion springs are ava ilable for some shocks if a firmer ride is desired.
38 THE PERFECT FIT EDGE 136 Rear Suspension Adjustment s Suspension Coupling Rear T o Front Coupling and the Rear Rear Scissor S top (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque ar m and limits the am ount o f indepen- dent moveme nt between the rear to rque and the front torq ue arm.
39 THE PERFECT FIT EDGE 136 Rear Susp ension Adjustment s W eight T ransfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding condi- tions.
40 THE PERFECT FIT Handlebar Adjustment Follow these steps to adjust handle bar angle at the hand lebar block. 1. Remove the handleb ar cover to expose the handlebar and the four adjuster block bolts.
41 THE PERFECT FIT T raction Product s Stu d s Before equipping your machine with traction products, be aware of the laws in your area pertaining to th e use of traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance.
42 THE PERFECT FIT T raction Product s n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to a ssist in turning the snowmob ile and to prevent ski wear caused by contact with roads and other bare terrain. Us e carbide skags with studded tracks to help maintai n proper vehicle steering and con trol.
43 THE PERFECT FIT T raction Product s W ear Strip s T o avoid excessive tunnel wear , tunnel wear strips must be installed whenever track studding is used. See your dealer for more information. W ear strips are designed for a specific stud length. See your dealer's studding chart for recommended traction accessories.
44 THE PERFECT FIT Accessories Polaris of fers a wide range of accesso ries for your snowmobile to h elp make each ride more enjoyable. Use only Polaris parts and accessorie s on your Polaris snowmobile.
45 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on th e checklist for proper operation or condition before each use of the snowmobile. Pr ocedures are outlined on the re fer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspect ion items.
46 PRE-RIDE INSPECTIONS Before St arting the Engine Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation.
47 PRE-RIDE INSPECTIONS Before St arting the Engine n Hydraulic Brakes Always check the following items fo r proper operation before starting the engin e. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip th an 1/2 I (1.
48 PRE-RIDE INSPECTIONS Before St arting the Engine n Parking Brake Lever Lock Y our snowmobile may have a parking brake lever lock located over the brake lever . Use the brake lever lock on ly when you want the machine to remain sta- tionary; for example, when parked on an incline for a period of five minutes or less.
49 PRE-RIDE INSPECTIONS Before St arting the Engine n S teering System W ARNING! Ice and snow build-up may in terf ere with the steering of your machine, resulting in serio us injury or death.
50 PRE-RIDE INSPECTIONS Before St arting the Engine n Hood Latches The hood of the sn owmobile protects the op erator from moving parts as well as aiding in sound e mission control and other functio ns. Under no circumstances should your snowmobile be operated with the hood open or removed.
51 PRE-RIDE INSPECTIONS S t art the Engine and Check n Engine S top Switch Check the auxiliary shut-of f switch for proper operation. Push the switch down to stop the engine . Pull it up to allow restarting. n Ignition Switch Make sure the engine stops when th e ignition switch is turned to OFF .
52 OPERA TION S t arting the Engine NOTICE: Engaging the starter when the engi ne is running WILL result in serious engine damage, especi ally if the tr ansmission is in r everse. Never engage the starter when the engi ne is running. 1. T urn the fuel valve on.
53 OPERA TION Engine Break-In No single action on yo ur part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of fuel with one pint of Polaris injection oil for each five gal- lons of fuel.
54 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 59. NOTICE: Serious engine damage can occur without the prope r lubrication. Check the oil tank level often during t he first tank of fuel. If the oil level doesn't go down, contact your dealer immediately .
55 OPERA TION T rack W arm-Up W ARNING! Use of traction products such as studs, ice g rowsers, etc. will increase the possibi lity of track damage and /or failure. This could cause lo ss of control, resulting in serious inj ury or death. Always inspect for track damage before operating the snowmobile.
56 OPERA TION Slide Rail and T rack Cooling NOTICE: Inadequate cooling an d lubrication will lead to overheating of the slide rail and track, resulti ng in prematur e wear and failure . Reduce speeds and frequently drive into fresh s now to allow adequate cooli ng and polishing of the slide ra il and tra ck surfaces.
57 OPERA TION Fuel Fuel V alve T urn the fuel valve clockwis e to OFF to shut of f the fuel supply . T urn the valve counter-clockwise to ON to turn the fuel supply on. Fuel Recommendations Y our Po laris engine is designed to run on 87 octane n on-oxygenated or 89 octane oxygenated pu mp gasoline.
58 OPERA TION Fuel Fuel Reserve Cap acity (Mechanical Gaug e) There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES. Fuel System Deicers If you use non-oxy genated fuel, Polari s re commends th e regular u se of isopropyl-based fu el system deicer .
59 OPERA TION n Oil Low Oil Indicator Light The low oil indicator light will alert th e operator if the oil level is low . V isually check for oil in the bottle. If oil is not visible, continued opera- tion may cause serious engine damag e. Add oil before further operation of the snowmobile.
60 OPERA TION Carburetion Proper carburetor adjustment is critical. Always have your Polaris dealer perform any carburetor adjustments. A lean mixture (too much air , too li ttle fuel) may result in piston burn- ing, bearing failure, or complete engine failure.
61 OPERA TION Carburetion Jetting Guidelines Changes in altitude and temperatur e affect air density , which is the amount of oxygen available for com bustion. In low elevations and cold temperatures, the air has more oxygen . In higher e levation s and high er temperatures, the air is less dense.
62 OPERA TION n Engine S top Switch Push down on the engine stop switch ( + ) to ground ou t the ignition and stop the engine quickly . Pull the switch up to the ON position to allow restarting.
63 OPERA TION Throttle Lever W ARNING! An improperly functioning thro ttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or dea th. If the throttle lever does not work prope rly , DO NOT start the engine.
64 OPERA TION Emergenc y S topping The following chart lists methods for stopping the snowmobile in the event of an emer gency . See page 62 for more information about the engine stop switch and throttle safety switch. W ARNING! Excessive or repetitive use of brakes for high speed stops will cause an over heated brake system.
65 OPERA TION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine RP M is below 4000. If your machine is running at an altitude of over 6000 feet, adju st the igni- tion setting as described on page 67. Al ways make sure the vehicle is stopped and the engine is running at idle before shifting to reverse.
66 OPERA TION Electronic Reverse (PERC t ) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear . 3. Push the yellow reve rse but- ton ( + ) on the left-hand con- trol for one second, the n release.
67 OPERA TION Electronic Reverse (PERC t ) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. NOTICE: Engaging the starter when th e engine is running WILL resul t in serious engine damage, especi ally if the tr ansmission is in r everse.
68 OPERA TION To w i n g Do not use the f ront bump er to pull or drag the snowmobi le. The front bumper is not de signed for this type of use and may detach from th e vehicle if force is applied. For your safety , do not attempt to use a tow hitch until you've read the following warnings and u nderstand the proper hitch functions.
69 MAINTENANCE Emission Control Information Any qualified repair shop or qualifie d person may maintain, replace, or repair the emission control device s or systems on your snowmobile.
70 MAINTENANCE Polaris Recommended Maintenance Program T o 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 L og beginning on page 128.
71 MAINTENANCE Periodic Maintenance Interval T a ble The following chart is a guide based on average riding condition s. Y ou may need to increase frequency based on ri ding conditions. When inspection reveals the need for replacement pa rts, always use genuine Polaris parts, available from your Polaris dealer .
72 MAINTENANCE Periodic Maintenance Interval T a ble Item See Page Frequenc y 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season BRAKES Hose Routing -- II II Hose Cond.
73 MAINTENANCE Periodic Maintenance Interval T a ble I - Inspect (clean, adjust, tighten, lub ricate, replace if necessary) C - Clean R - Replace L - Lubricate Item See Page Frequenc y 150 mi.
74 MAINTENANCE Lubrication Suspension and Steering Lubricate the suspension and steer ing components with Polaris Pre- mium All-Season Grease at 500 mile s (800 km) and annually or every 1000 miles (1600 km) thereafter . See page 1 1 1 for the pa rt numbers of Polaris products.
75 MAINTENANCE Lubrication EDGE 136 Rear Suspension Driveshaf t Bearing Inject grease into th e fitting on the speed- ometer sensor housing until grease pur ges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps.
76 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at th e intervals outlined in the mainte- nance charts beginning on pa ge 70 . Change the chaincase oil after the first 500 miles (800 km), t hen every 1000 miles (1 600 km) or season- ally .
77 MAINTENANCE Spar k P l u g s It’ s very important to use the corre ct spark p lug for your machine. A spark plug with a heat range too hi gh will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.
78 MAINTENANCE Spar k P l u g s Normal Plug The normal insulator tip is gray , ta n 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.
79 MAINTENANCE Int ake Filters The intake foam filter ( + ) l imits snow ingestion into the intake system. When operating in loose powder snow , check the top of the foam filter periodically to re move any accum ulation of snow . NOTICE: Operating the sno wmobile with the i ntake filters removed may cause carburetor icing.
80 MAINTENANCE Fuel Filter/Fuel Lines The fuel filter is located inside th e fuel tank. This component requires no maintenance. Inspect the fuel lines re gularly for signs of deterior ation or damage. Always check fuel line condition after periods of storage.
81 MAINTENANCE Carburetor The numb er 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. It's your dealer's responsi bility to make sure the correct main jet is installed.
82 MAINTENANCE Carburetor W ater/Sediment T rap Service Most Polaris snowmobiles contain pa tented carbure tor bowl water/sedi- ment traps located at the bottom of each carburetor . The trap, consisting of a hose with a plu g, should be drained at least every 2000 miles (3 200 km) and inspected for contamination.
83 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at ap proximately 2000 miles (3200 km). T o inspect, allow the engine and exhaust system to cool completely . Open the hood an d inspect the muffler and pipes for cracks or damage.
84 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 47. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approxima tely 1/16 inch/1.
85 MAINTENANCE Brakes Brake Fluid W ARNING! Af ter opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.
86 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spon gy brake lever action. Bleed the system before operating the snow mobile. W ARNING! Operating the vehicle wi th a spongy brake lever can result in loss of brakes, which could cause an accident and lead to seriou s injury or death.
87 MAINTENANCE Light s Headlight Adjustment The headlight may be adjusted for ve rtical aim using the following pro- cedure. 1. Place the snowmobile on a level surface with the he adlight approxi- mately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floo r to the center of the headlight and make a mark on the wall.
88 MAINTENANCE Light s NOTICE: Do not touch a halogen bulb wi th bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb, clean it with an alcohol-moistened to wel. Headlight Bulb Replacement 1.
89 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. T o maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. NOTICE: If you become aware of higher than normal clutch engage ment or an unusual vibration or shift p attern, see your dealer immedi ately .
90 MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operat ing in a forward motion. NOTICE: Do not attempt to remove th e drive belt after ope rating i n reverse. The snowmobile must be stopped after forward motion to preven t damage to components during bel t removal.
91 MAINTENANCE Clutch System Drive Belt Inst allation 1. Drop the drive belt over the drive clutch and pull back the slac k. Tip : T o ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identifica tion numbers so that you can read them.
92 MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and ap ply downward pre ssure while measuring at point 2. This measurement sh ould be 1 1/4 inches (32 mm).
93 MAINTENANCE Clutch System T orque S top If your snowmobile is equipped with an engine torque stop, periodically check torque stop clearance. W ith clutches in proper alignment, the torque stop clearance should be .010- .030 inch (.25-.75 mm) from the engine c ase.
94 MAINTENANCE Chain T ension Maintain the proper chain tens ion as outlined on page 83. Fall T une-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer . His experienced and tr ained service technician will keep your machine in peak operating condition.
95 MAINTENANCE Tr a c k T rack Inspection W ARNING! Broken track rods can cause a rotating track to come off the machine, which could cause seriou s in jury or death. N ever operate wi th a damaged track. Never rotate a damaged track under power . 1. Using a hoist, safel y lift and support the rear of the snowmobile of f the ground.
96 MAINTENANCE Tr a c k Moving part s can cut and crush body part s. When performing the checks and adjustments recommended on the following pages, stay clear of all moving part s. Never perform track measurement or adjustments with the engine run- ning.
97 MAINTENANCE Tr a c k T rack T ension If the track needs adjustment: 6. Loosen the rear idler shaft bolts. 7. Loosen the locknuts. 8. T ighten or loosen the track adjusting screws to provide equal adjustment on both sides of the track. 9. Repeat the measure - ment on the other side of the track.
98 MAINTENANCE Tr a c k n T rack Alignment Periodically check that the track is centered and runnin g evenly on the slide rails. Misalignment will cause exce ssive wear to the track and slide rail. 1. Safely support the rear of the ma chine with the track off the ground.
99 MAINTENANCE S teering System n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum permissible slide thickness. Replace the rail slides if they are worn to the top of the groove at an y point along their length.
100 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment o r adjust ment may cause loss of steering control, resulting in serious inj ury or death. Do not attempt to cha nge the ski alignment or camber adjustmen t. See your Polaris dealer .
101 MAINTENANCE S teering System n Ski Skags See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide sk ags than the original equipment, it may also be necessary to add track st uds to maintain proper vehicle con- trol while turni ng on hard-pack ed snow or ice.
102 MAINTENANCE Battery Battery electrolyte is poisono us. It contai ns acid! Serious burns can resu lt from contact with the skin, eyes, or clo thing. If contact occurs, seek immediate medi- cal attention. KEEP OUT OF REACH OF CHILDREN. EXTERNAL: Flush with water .
103 MAINTENANCE Battery Battery Removal W ARNING! Improperly connecting or disconnecti ng battery cables can result in an explosion and cause serious inju ry or death. When removing the battery , always disconnect the neg ative (black) cable first. When re installing the battery , always connect the negative (black) cable last.
104 MAINTENANCE Battery Battery Inst allation W ARNING! Battery electrolyte contains acid. Avoid skin contact with electrolyte as severe burns may result. Using a new battery that has not been fully char ged can damage the bat- tery and result in a shorter life.
105 MAINTENANCE Battery Batter y S torage When your snowmo bile is placed in storage for one month or more: • Remove the battery . • Char ge it to the proper level. • S tore it in a cool dry place. • Check and/ or charge monthly . • Have the battery tested and rechar ged before reinstalling it in the vehicle.
106 MAINTENANCE n Pre-Ride Suspen sion Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Befo re beginning any snowmobile trip, a visual inspection will uncover po tential problems.
107 MAINTENANCE Extended S torage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many compon ents. See page 1 1 1 for the part n umbers of Polaris prod- ucts.
108 MAINTENANCE Extended S torage Bearings Grease the drive shaft c lutch side bearing with Polaris Premium All- Season Grease or a similar high qu ality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location.
109 MAINTENANCE Extended S torage Engine and Carbur etor Protection Using a fuel stabilizer and topping of f the fuel tank eliminates the need to drain the fuel system. If you prefer to drai n the fuel tank, use the fol- lowing procedure 1. T ransfer un used fuel from the fuel ta nk to an appro ved fuel con - tainer using a siphon pump.
110 MAINTENANCE Extended S torage Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack conn ector blocks with diel ectric grease and re-connec t. Replace worn or frayed electrical wi re and conn ectors.
111 POLARIS PRODUCTS Part No. Description Engine Lubric ant s 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.
112 TROUBLESHOOTING Engine T r oubleshooting Unless you have experience and traini ng in two-cycle engine repair , see your dealer if technical problems arise.
113 TROUBLESHOOTING Engine T r oubleshooting Problem Probable Cause Solution Noise in drive sys- tem Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, jackshaft, or front drive shaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed.
114 TROUBLESHOOTING Engine T r oubleshooting Problem Probable Cause Solution Engine turns but fails to start Faulty ignition • Install new spark plug(s). If engine still fails to start , check for spark. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is on.
115 TROUBLESHOOTING EDGE 136 Suspension Problem Solution Rear suspension bottoms too easily • Increase torsion spring preload • Increase rear shock compre ssion damping by turning screw clockwise • Increase torsion spring wire diameter (see your dealer) • Rotate RRSS to a higher position.
116 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at l ow RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • W arm the engine at least five minutes. T ake the drive belt of f the machine in extrem ely cold weather and warm it up.
117 W ARRANTY Service and W a rranty Information Obt aining Service and W arranty Assist ance Read and understand the service data and the Polaris warranty informa- tion contained in this manual. Contact your Polaris dealer for replace- ment parts, service or warra nty .
118 W ARRANTY Service and W a rranty Information Polaris Anti-Thef t System The Polaris anti-theft system (P A T S) monitoring prog ram is design ed to aid owners of registered snowmobil es in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft.
119 W ARRANTY Limited W arranty Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, provides a ONE YEAR LIM- ITED W ARRANTY on all components of the Polaris snowmobile against defects in material or workma nshi p.
120 W ARRANTY Limit ations of warranties and remedies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P A R- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD.
121 W ARRANTY Conditions and Ex clusions In order to qualify for warranty , the product must have been prop erly set up and tested by a Polaris Dealer (if applicable).
122 W ARRANTY Polaris Second Y ear Engine Service Contract Second Y ear Engine Service C ontr act is standard on all el igible new and unused snow- mobiles that were Snow Checked through an authorized Polaris dealer d uring the March/April Snow Check promot ion.
123 W ARRANTY Polaris Second Y ear Engine Service Contract Coverage Coverage for second year en gine failures d ue to defects in materials and workmanship will be determined by Polaris in its sol e di scretion. Coverage is automatic with no addi- tional paperwork required.
124 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LO CA- TION. This policy does not apply to vehicles that hav e received authorization for export from Polaris Industries.
125 W ARRANTY Exported V ehicles How to Get Service In the Country whe re your vehicle was purchased: W a rranty or Service Bulletin repairs must be done by an authorized Polaris dealer .
126 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions limited war ranty is in add ition to the Polaris standard lim ited warranty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified veh icle is designed, built and equipped so it conforms with applica- ble U.
127 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive rem edy for breach of this limited warrant y shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts.
128 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 servi ces performed on the snowmobile. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi.
129 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS.
130 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS.
131 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS.
132 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 44 Air Box Warnin g . . . . . . . . . . . . . . . 22 Air Pollut ion . . . . . . . . . . . . . . . . . . . 5 Altitude S etting . . . . . . . . . . . . . . . . 67 Avalanches . . . . . . . . .
133 INDEX H Handlebar Adjust ment . . . . . . . . . . . 40 Headlight A djustment . . . . . . . . . . . . 87 Headlight Bul b Replacement . . . . . . 88 Hood Latches . . . . . . . . . . . . . . . . . . 50 I Ice and Snow Bu ild-up . . . . . . . . . . . 15 IFS .
134 INDEX S Survival Preparation . . . . . . . . . . . . 10 Suspension Adjustments . . . . . . . 34-39 Suspension Adjustments, Front . . 29-31 Suspension Adjustments, Rear . . 32- 33 Suspension Coupling . . . . . . . . . . 37-38 Suspension Inspection, Pre-Ride .
An important point after buying a device Polaris Trail Touring (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris Trail Touring yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris Trail Touring - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris Trail Touring you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris Trail Touring will certainly help you make a decision on the purchase.
If you already are a holder of Polaris Trail Touring, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris Trail Touring.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris Trail Touring. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris Trail Touring along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
