2002 Polaris Universal Snowmobile Owners Manual
2002 Polaris Universal Snowmobile Manual
2002 Polaris Universal Snowmobile manual content summary:
- 2002 Polaris Universal Snowmobile | Owners Manual - Page 1
- 2002 Polaris Universal Snowmobile | Owners Manual - Page 2
Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. PROPOSITION 65 WARNING Snowmobile engines discharge fuel - 2002 Polaris Universal Snowmobile | Owners Manual - Page 3
What's the hottest thing on snow? Our new web site. It's designed just for YOU! S S S S S Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out...www.polarisindustries.com/owner 1 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 4
- NOTES - 2 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 5
we've ever produced. Follow the instructions and recommendations in this Owner's Manual for safe and enjoyable operation of your vehicle. Your Owner's Manual contains instructions for minor maintenance, but major repairs are covered in the Polaris Service Manual and should be performed by a Factory - 2002 Polaris Universal Snowmobile | Owners Manual - Page 6
important identification numbers that should be recorded in your Owner's Manual. Section 2 - Safety ...11 - 34 This section describes snowmobile's regular maintenance. Section 8 - Troubleshooting ...157 - 166 This section is a quick reference guide to solving problems. Section 9 - Warranty ...170 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 7
Numbers ...9 Section 1 contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in your Owner's Manual. It also defines your role in protecting and respecting your environment while experiencing The Way Out. 5 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 8
, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. n This manual contains the latest information at the time of printing. We reserve the right to make product changes and improvements without notice. n The illustrations and photos - 2002 Polaris Universal Snowmobile | Owners Manual - Page 9
HOW TO USE THIS MANUAL Preservation Of The Environment Please operate your snowmobile with consideration for the protection and preservation of our environment. Noise Level One of the most publicized - 2002 Polaris Universal Snowmobile | Owners Manual - Page 10
HOW TO USE THIS MANUAL Preservation Of The Environment Polaris is committed to supporting an environmental education campaign. We encourage and other organizations are working together to protect our environment. Please support their efforts and do your part to preserve and protect our environment - 2002 Polaris Universal Snowmobile | Owners Manual - Page 11
HOW TO USE THIS MANUAL Vehicle Identification Numbers Please record your snowmobile identification numbers below for future reference: Tunnel VIN (lower right side of the tunnel) Engine Serial Number (right - 2002 Polaris Universal Snowmobile | Owners Manual - Page 12
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SECTION 2 - SAFETY Operator Safety ...12 - 27 Safety Decals and Locations ...28 - 34 Section 2 describes safe vehicle operation and identifies warning decals and their locations. 11 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 14
Become familiar with their meanings before reading the manual. The safety alert symbol, on your snowmobile or in this manual, alerts you to the potential for personal injury. will alert you to important information or instructions. IMPORTANT "IMPORTANT:" will alert you to important information or - 2002 Polaris Universal Snowmobile | Owners Manual - Page 15
SAFETY Operator Safety 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, it's prohibited by law to drive while intoxicated or - 2002 Polaris Universal Snowmobile | Owners Manual - Page 16
warming up the track. A loose track or flying debris could cause serious personal injury or death. We recommend having your dealer perform track service and alignment procedures. Be alert when riding, and remain properly seated to stay clear of the track. Your snowmobile is propelled by a revolving - 2002 Polaris Universal Snowmobile | Owners Manual - Page 17
SAFETY Operator Safety Be Seated and in Position to Control the Vehicle WARNING Improper riding position may seriously reduce your ability to control the machine and may result in serious injury or death. Always be properly seated and in position to control your vehicle. Operating a snowmobile - 2002 Polaris Universal Snowmobile | Owners Manual - Page 18
SAFETY Operator Safety Do Not Overload Cargo Carrier Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier. WARNING Control becomes more difficult with two - 2002 Polaris Universal Snowmobile | Owners Manual - Page 19
SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Know the Limitations of the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 20
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 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 21
may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. 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 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 22
SAFETY Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Operating in hilly terrain requires extreme - 2002 Polaris Universal Snowmobile | Owners Manual - Page 23
, don't defeat the purpose of the guard by removing it. It's provided for your safety. Do Not Operate Engine With Drive Belt Removed Any servicing that requires operation without a belt must be performed by your dealer. Operation of the engine with the belt removed may result in personal injury or - 2002 Polaris Universal Snowmobile | Owners Manual - Page 24
the intake silencer or filter are removed. Do Not Service Clutches Yourself All clutch service must be performed by your dealer. The clutch is respect for a passenger. See page 74 for more detailed instructions on cold weather drive-away. Machine Maneuverability Control and maneuverability comes - 2002 Polaris Universal Snowmobile | Owners Manual - Page 25
SAFETY Operator Safety Powder Snow Operation Moveable hood closures are included on some Polaris snowmobiles. They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20_F), Polaris recommends closing the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 26
is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 96 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. Driving 1-Up - 2002 Polaris Universal Snowmobile | Owners Manual - Page 27
SAFETY Operator Safety Responsible Driving Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the machine and with what it will and won't do under various conditions. Even - 2002 Polaris Universal Snowmobile | Owners Manual - Page 28
SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART (°F) Estimated Wind Speed in MPH Actual Thermometer Reading (°F) 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60 Equivalent - 2002 Polaris Universal Snowmobile | Owners Manual - Page 29
SAFETY Operator Safety WIND CHILL CHART (°C) Estimated Wind Speed in KPH Actual Thermometer Reading (°C) 5 0 -5 -10 -15 -20 -25 -30 -35 -40 Equivalent Temperature (°C) 0 10 20 30 40 50 60 70 Wind Speeds Greater Than 70 KPH Have Little Added Effect 5 1 -4 -7 -9 -11 -12 -13 0 -4 -9 -13 -16 -18 -19 - - 2002 Polaris Universal Snowmobile | Owners Manual - Page 30
vehicle for your protection. Read and follow the instructions on each decal carefully. If any safety decal becomes guard open. Never run engine with drive belt removed. Never service clutches yourself - see your dealer. Airbox Warning Decal - Manual for fluid level in overflow bottle. 1, 2, 3 28 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 31
not exceed 40 lbs. (18 kg). Cargo load affects machine steering and response. Never allow person(s) to use carrier as a means of hand support, (skiing, skidding or dragging). Severe injury may result due to track entanglement, falling off, or loss of steering control if warnings are not followed - 2002 Polaris Universal Snowmobile | Owners Manual - Page 32
SAFETY Safety Decals And Locations Passenger Warning - 5 Some snowmobiles are designed for the operator only, while others are designed for the operator and one passenger. A warning decal on either the console or the hood of your machine indicates whether it's designed for the operator only (1-Up) - 2002 Polaris Universal Snowmobile | Owners Manual - Page 33
the shift lever. Always apply throttle slowly. On machines with reverse it is especially important to maintain track tension as specified in the Owner's Manual. If specified track tension is not maintained severe damage to the machine may occur, which may result in loss of vehicle control. Loss of - 2002 Polaris Universal Snowmobile | Owners Manual - Page 34
S S S and while backing Avoid sharp turns. Shift to or from reverse only when stopped. Apply throttle slowly. For more information, see your Owner's Manual. Operation Warning Decal - 8 The console of your machine has a WARNING decal. The location of this decal will depend on the model you own. The - 2002 Polaris Universal Snowmobile | Owners Manual - Page 35
Operation Warning Decal Text: S Read and understand warnings and the Owner's Manual before S S S S S operation. Severe injury or death can result track studs to maintain proper vehicle control. (See the Owner's Manual for proper use of traction accessories.) Never permit a guest to operate this vehicle - 2002 Polaris Universal Snowmobile | Owners Manual - Page 36
to control vehicle. Stop engine before attempting adjustments. Know the limitations of the vehicle and your skills as a driver. Understand your Owner's Manual. Wear clothing designed for snowmobiling. Stops from high speed may cause fading or unexpected loss of braking ability. Oil injection system - 2002 Polaris Universal Snowmobile | Owners Manual - Page 37
SECTION 3 - FEATURES AND CONTROLS Location of Controls ...36 - 38 Features ...39 - 41 Section 3 illustrates the locations of your snowmobile's controls and features. 35 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 38
FEATURES AND CONTROLS Location of Controls NOTE: Your machine may not look exactly like the illustration, but these controls are found in the same general area on all machines. 4 5 6 3 7 8 2 1 10 9 1. Fuel Filler Cap (some models have a fuel gauge in the cap) 2. Ignition Switch 3. Brake Lever - 2002 Polaris Universal Snowmobile | Owners Manual - Page 39
features. Controls for these features are illustrated on this page. Not all models come with these features. Refer to your Owner's Manual Supplement for a list of features on your machine. Accessories are available from your Polaris dealer. 1. Headlight Dimmer Switch (2 Position) 2. Park Brake - 2002 Polaris Universal Snowmobile | Owners Manual - Page 40
features. Controls for these features are illustrated on this page. Not all models come with these features. Refer to your Owner's Manual Supplement for a list of features on your machine. Accessories are available from your Polaris dealer. 2 1 3 1. Reverse Indicator Light 2. Electronic Fuel Gauge - 2002 Polaris Universal Snowmobile | Owners Manual - Page 41
FEATURES AND CONTROLS Features 3 2 16 1 17 4 8 20 5 10 6 7 18 12 15 14 13 11 9 21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hood Headlight Windshield Handlebar Seat Storage/Rear Taillights Backrest Tunnel Extension Passenger Hand Hold Strap Track 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Suspension - 2002 Polaris Universal Snowmobile | Owners Manual - Page 42
FEATURES AND CONTROLS Features 3 22 1 16 2 4 5 6 18 7 21 15 13 14 12 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Hood Headlight Windshield Handlebar Seat Storage/Rear Taillights Backrest Tunnel Extension Passenger Hand Hold Strap Track 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Suspension Nosepan - 2002 Polaris Universal Snowmobile | Owners Manual - Page 43
FEATURES AND CONTROLS Features 3 2 1 16 17 4 5 8 10 20 6 7 15 13 14 12 11 9 21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hood Headlight Windshield Handlebar Seat Storage/Rear Taillights Backrest Tunnel Extension Passenger Hand Hold Strap 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Suspension Nosepan - 2002 Polaris Universal Snowmobile | Owners Manual - Page 44
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SECTION 4 - THE PERFECT FIT Front Suspension Adjustments ...44 - 48 Rear Suspension Adjustments ...49 - 58 Handlebar Adjustment ...59 Backrest Adjustment ...59 Accessories ...60 - 63 Polaris offers a wide range of adjustments so that every machine may be set up to suit individual needs. This section - 2002 Polaris Universal Snowmobile | Owners Manual - Page 46
THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts before fine-tuning adjustments are made. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. - 2002 Polaris Universal Snowmobile | Owners Manual - Page 47
THE PERFECT FIT Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page145 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spring is set is - 2002 Polaris Universal Snowmobile | Owners Manual - Page 48
THE PERFECT FIT Front Suspension Adjustments Adjusting Front ShockSpring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure springs on both the left and right sides of the machine are at the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 49
, 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. This work should be performed by a Polaris dealer. 47 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 50
THE PERFECT FIT Front Suspension Adjustments Indy Select IFS Shock Some snowmobiles are equipped with Indy Select IFS shocks, which allow you to make adjustments to the compression valving of the front shocks by turning adjustment screws (A) located near the base of the shocks. By turning the screw - 2002 Polaris Universal Snowmobile | Owners Manual - Page 51
THE PERFECT FIT Rear Suspension Adjustments Rear Suspensions Polaris has six different rear suspension packages, each designed and set up to deliver a soft ride under average riding conditions. Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear - 2002 Polaris Universal Snowmobile | Owners Manual - Page 52
THE PERFECT FIT Rear Suspension Adjustments Rear Suspension Initial Spring Preload Setting EDGE RMK (Sag Method) To set up the EDGE RMK rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take this measurement with no rider X and - 2002 Polaris Universal Snowmobile | Owners Manual - Page 53
THE PERFECT FIT Rear Suspension Adjustments Rear Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information. The following - 2002 Polaris Universal Snowmobile | Owners Manual - Page 54
THE PERFECT FIT Rear Suspension Adjustments Rear Suspension Initial Spring Preload Setting Xtra-10, EDGE and Xtra Lite (Sag Method) To set up the EDGE rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement - 2002 Polaris Universal Snowmobile | Owners Manual - Page 55
THE PERFECT FIT Rear Suspension Adjustments Rear Torsion Spring Adjustment - Xtra-12 To adjust rear torsion spring tension, rotate the two-position cam using the engine spark plug tool. 1a - Soft Tension - long end of cam to front 1b - Medium Tension - short end of cam up Different rate torsion - 2002 Polaris Universal Snowmobile | Owners Manual - Page 56
THE PERFECT FIT Rear Suspension Adjustments Indy Select Front Track Shock Some snowmobiles are equipped with the Indy Select front track shock, which allows the driver to make adjustments to the compression valving by turning the screw located near the base of the shock. Adjustment Locate the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 57
THE PERFECT FIT Rear Suspension Adjustments Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock. Adjustment Locate the adjustment screw (A) - 2002 Polaris Universal Snowmobile | Owners Manual - Page 58
kit available for increasing damping. If you desire to have the internal valving changed, consult your dealer, or refer to the suspension troubleshooting decal located under your hood or on the clutch guard. Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms - 2002 Polaris Universal Snowmobile | Owners Manual - Page 59
THE PERFECT FIT Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque - 2002 Polaris Universal Snowmobile | Owners Manual - Page 60
Position (optional hole location - This setting will increase weight transfer. NOTE: Your dealer can help you with initial set-up and additional set-up instructions to help you achieve your optimum ride. Xtra-12 Rear Rear Scissor Stop (RRSS) The RRSS on Xtra-12 suspensions is not adjustable. 58 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 61
THE PERFECT FIT Handlebar Adjustment Follow these steps to adjust the handlebars for a personal fit. 1 Remove the handlebar cover to A expose the handlebar and the four adjuster block bolts (A). 2 Using a 7/16″ (11 mm) wrench, loosen the four nuts on the bottom of the adjuster block (turn handlebar - 2002 Polaris Universal Snowmobile | Owners Manual - Page 62
, clutches, fuel systems, and exhaust systems. NOTE: Exhaust systems are critical safety areas that must use approved Polaris parts. Please see your Polaris dealer for service. 60 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 63
THE PERFECT FIT Accessories Traction Products Another way to tailor your machine is to install traction products. See your dealer if you 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. NOTE: - 2002 Polaris Universal Snowmobile | Owners Manual - Page 64
THE PERFECT FIT Accessories Traction Products IMPORTANT: Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. Track studding will enhance braking control on hard-packed snow or ice, but extreme caution is still required - 2002 Polaris Universal Snowmobile | Owners Manual - Page 65
. See your dealer for more information. Some models are manufactured with tunnel wear strips or wear strip coolers installed. Refer to your Owner's Manual Supplement to determine if your model has wear strips. Wear strips are designed for a specific stud length. See your dealer's studding chart for - 2002 Polaris Universal Snowmobile | Owners Manual - Page 66
- NOTES - 64 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 67
SECTION 5 - GETTING READY TO RIDE Check Before Starting Engine ...66 - 70 DThrottle Freeplay DBrake DFluid Levels DSteering DMirrors DGear Start the Engine and Check ...71 DLights DStop Switch DSkis and Track (cold/warm) DPre-ride warm-up Certain items must be checked before each ride. This section - 2002 Polaris Universal Snowmobile | Owners Manual - Page 68
to be sure of proper operation. Read and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. We've attempted to provide not function smoothly, DO NOT start the engine. Have the throttle serviced immediately. The need for a properly functioning brake is critical. - 2002 Polaris Universal Snowmobile | Owners Manual - Page 69
the fluid. Also check for the presence of air in the fluid system. Refer to page 127 for more information, or see your dealer for service. Replace brake fluid at least every two years with Polaris DOT 3 high temperature brake fluid. All DOT 3 brake fluid is not alike. Use only Polaris - 2002 Polaris Universal Snowmobile | Owners Manual - Page 70
GETTING READY TO RIDE Check Before Starting Engine Mechanical Brakes Brake Lever Travel Firmly depress the brake lever. Measure the distance (A) between the lever and brake block. The distance should be no more than 3/4″ (1.9 cm). If the distance is greater than this recommendation, the brake cable - 2002 Polaris Universal Snowmobile | Owners Manual - Page 71
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 all models have a park brake) 3. Master Cylinder Reservoir / Cover 4. Fluid Level Indicator 4 3 2 1 WARNING - 2002 Polaris Universal Snowmobile | Owners Manual - Page 72
GETTING READY TO RIDE Check Before Starting Engine Check for Proper Operation of Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may - 2002 Polaris Universal Snowmobile | Owners Manual - Page 73
GETTING READY TO RIDE Start The Engine And Check n Transmission: Make sure the reverse is not engaged before starting your machine. n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and start the engine. n Tether Switch: - 2002 Polaris Universal Snowmobile | Owners Manual - Page 74
- NOTES - 72 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 75
SECTION 6 - OPERATION Starting Your Engine ...74 - 75 Engine Break-In ...76 - 77 Track Warm-Up ...78 - 79 Fuel ...80 - 82 Oil ...83 - 84 Carburetion ...85 Engine Stop Switch ...86 Throttle Safety Switch ...86 Throttle Lever ...87 Emergency Stopping and Starting ...88 - 89 Reverse Operation ...90 - - 2002 Polaris Universal Snowmobile | Owners Manual - Page 76
your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 66. Starting a Cold Engine (Manual Start) Do not depress the throttle until the engine starts. 1 Turn key to "ON." 2 Pull kill switch (shut-off switch) up to "RUN - 2002 Polaris Universal Snowmobile | Owners Manual - Page 77
OPERATION Starting Your Engine Starting a Cold Engine (Electric Start) Do not depress the throttle CHOKE TOGGLE POSITIONS until the engine starts. 1 Flip choke toggle to "FULL ON." or Off 2 Pull kill switch (shut-off switch) up to "RUN." 3 Turn key to "START" and crank engine. or Half On 4 After the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 78
OPERATION Engine Break-In No single action on your 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 gasoline with one pint of Polaris injection oil - 2002 Polaris Universal Snowmobile | Owners Manual - Page 79
OPERATION Engine Break-In Oil Injection System CAUTION Check the oil tank level often during the first tankful of fuel. If the oil level doesn't go down, contact your dealer immediately. Always fill the oil reservoir when refueling. Fuel-to-oil mix ratios are controlled by the oil pump and - 2002 Polaris Universal Snowmobile | Owners Manual - Page 80
when track is free-hanging. Be sure the rear support is stable. NOTE: The outside temperature will determine the amount of track warm-up required. With the snowmobile securely supported by the rear bumper, and the track approximately 4″ (10 cm) - 2002 Polaris Universal Snowmobile | Owners Manual - Page 81
OPERATION Track Warm-Up 5 The engine, drive system and track are now properly warmed up and the machine may be driven following normal safety practices. WARNING Always inspect for track damage before operating the snowmobile. Use of traction products such as studs, ice growsers, etc. will increase - 2002 Polaris Universal Snowmobile | Owners Manual - Page 82
OPERATION Fuel Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not overfill - 2002 Polaris Universal Snowmobile | Owners Manual - Page 83
the country, so we encourage the use of premium fuel when possible. NOTE: Some Polaris snowmobiles require premium gasoline. Check your Owner's Manual Supplement to determine what type of fuel your machine requires. Premium Fuel Switch Some Polaris snowmobiles are equipped with a key function to - 2002 Polaris Universal Snowmobile | Owners Manual - Page 84
OPERATION Fuel Premium Fuel Switch If you're 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 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 85
OPERATION Oil Low Oil Indicator Light The low oil indicator light (standard on most models) will indicate when to add oil. However, always check the oil level when refueling. CAUTION When the low oil indicator light is on, oil should be added before further operation of the snowmobile. Visually - 2002 Polaris Universal Snowmobile | Owners Manual - Page 86
OPERATION Oil Low Oil Level Always do a visual check of the oil level when refueling. In the illustration, * indicates a low oil level. When the oil reaches the low level mark, add one U.S. quart of oil to the tank. Always use a Polaris oil cap, never substitute. Your Polaris oil cap may be vented - 2002 Polaris Universal Snowmobile | Owners Manual - Page 87
OPERATION Carburetion Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance. A lean - 2002 Polaris Universal Snowmobile | Owners Manual - Page 88
OPERATION Engine Stop Switch Push down on the engine stop switch (A) to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to "ON." A Throttle Safety Switch Test the throttle safety switch B - 2002 Polaris Universal Snowmobile | Owners Manual - Page 89
may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the machine to an authorized Polaris dealer for service. If an emergency exists and it's necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 90
OPERATION Emergency Stopping And Starting Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 86 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle - 2002 Polaris Universal Snowmobile | Owners Manual - Page 91
OPERATION Emergency Stopping And Starting Starting WARNING To prevent serious injury, DO NOT wind the start strap around your hand. Keep all bystanders away from the snowmobile when using the emergency starting procedure. Your machine is equipped with a tool kit containing essential tools for - 2002 Polaris Universal Snowmobile | Owners Manual - Page 92
OPERATION Reverse Operation (Mechanical) WARNING Misuse of reverse can result in serious injury or death. This snowmobile is capable of high speeds in reverse. Reverse operation may be dangerous even at moderate speeds. Steering control becomes difficult in reverse. Make sure the shift lever is - 2002 Polaris Universal Snowmobile | Owners Manual - Page 93
OPERATION Reverse Operation (Electronic) WARNING Reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. To avoid loss of control, always: S S S S Look behind before and while backing. Avoid sharp turns. Shift to or from reverse only when stopped. - 2002 Polaris Universal Snowmobile | Owners Manual - Page 94
memory until changed, whether the machine is running or not. Daily Storage At the end of your ride, park the snowmobile on a level surface and support it at the rear with the appropriate track stand. The track should be suspended approximately 4″ (20 cm) off the ground. Remove the key and cover - 2002 Polaris Universal Snowmobile | Owners Manual - Page 95
OPERATION Towing For your safety, the proper function of a tow hitch must be understood before attempting its use. WARNING DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a rope. No braking power can be applied to an object being towed with a rope. Only a stiff metal pole - 2002 Polaris Universal Snowmobile | Owners Manual - Page 96
- NOTES - 94 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 97
Battery ...153 - 155 This section defines your role, and your dealer's role, in your snowmobile's regular maintenance. If you're interested in more information about servicing your own machine, contact your dealer for a Polaris Snowmobile Service Manual. 95 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 98
Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks outlined in this manual. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles - 2002 Polaris Universal Snowmobile | Owners Manual - Page 99
MAINTENANCE Maintenance Chart The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use - 2002 Polaris Universal Snowmobile | Owners Manual - Page 100
plug condition Inspect coolant filter, replace if necessary Grease ski pivots Grease ski spindles Grease center steering arm(s) Lubricate steering post support bracket and pivot (aerosol) Check cylinder base stud torque on all Polaris engines. (Specification: 32 ft. lbs ± 2 ft. lbs.) (Dealer) Grease - 2002 Polaris Universal Snowmobile | Owners Manual - Page 101
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. 150 Mile (240 km) Initial Maintenance Inspection Authorized - 2002 Polaris Universal Snowmobile | Owners Manual - Page 102
MAINTENANCE Maintenance Log Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service Mileage Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service Mileage 100 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 103
both front ski pivots at fitting as shown. DGrease jackshaft and driveshaft clutch side bearings. DUse an aerosol lubricant on the steering post support bracket. DGrease center steering arms. DGrease steering post lower pivot. DRear suspension pivot shafts. Raise the rear of unit. A grease gun kit - 2002 Polaris Universal Snowmobile | Owners Manual - Page 104
MAINTENANCE Lubrication The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease (PN 2871066) at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication affects your ride and the life of your - 2002 Polaris Universal Snowmobile | Owners Manual - Page 105
MAINTENANCE Lubrication L L L L L L L L L 103 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 106
MAINTENANCE Lubrication L L L (Both sides) L L L L L L L 104 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 107
MAINTENANCE Lubrication L L L L L L L L L L L L 105 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 108
MAINTENANCE Lubrication Suspension Lubrication - X-10, EDGE L L L L L 106 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 109
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 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 110
MAINTENANCE Lubrication Throttle Cable Lubrication Lubricate the throttle cable (1) with Polaris Cable Lubricant (PN 2870510). With the engine off, turn the handlebars to the left and lubricate liberally as shown. Choke and Cable Lubrication Lubricate the choke slide (2) and cables with Polaris - 2002 Polaris Universal Snowmobile | Owners Manual - Page 111
MAINTENANCE Lubrication Chaincase Oil Level It's the operator's responsibility to check and maintain the proper chaincase oil level. 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 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 112
MAINTENANCE Lubrication Gearcase Oil Level (WideTrak Models) It's the operator's responsibility to maintain proper gearcase oil level. 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 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 113
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. CAUTION Operating the snowmobile with the intake filters removed - 2002 Polaris Universal Snowmobile | Owners Manual - Page 114
. This selection could cause the customer who normally operates the engine under medium or light duty to have spark plug failure. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your machine. CAUTION A plug with a heat range too high will always cause engine damage - 2002 Polaris Universal Snowmobile | Owners Manual - Page 115
the correct main jet is installed in the carburetor(s). Refer to the Owner's Manual Supplement or see your dealer. Normal: The insulator tip is gray, tan, plug is the proper type and heat range for the engine and the service. Overheating: The insulator tip is white. General causes are use of an - 2002 Polaris Universal Snowmobile | Owners Manual - Page 116
and remove it. 3 Install the new spark plug, rotating clockwise. 1 4 Torque to 18-22 ft. lbs. (2.5-3 kg/m). 5 Check spark plug gap (refer to your Owner's Manual Supplement). 6 Install spark plug cap. 114 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 117
inspection of the water pump belt at 1500 miles (2400 km). Inspect belt width (A) and condition, and 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. A 115 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 118
MAINTENANCE General Maintenance Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor anything that may cause the fuel to ignite, such as open flames, sparks, heaters, trouble lights, cigarettes, etc. Review the gasoline warnings found on page 80. Plug Cleaning Procedure - 2002 Polaris Universal Snowmobile | Owners Manual - Page 119
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. NOTE: The direction of the arrows indicates the direction of flow through - 2002 Polaris Universal Snowmobile | Owners Manual - Page 120
's responsibility to make sure the correct main jet is installed. CAUTION Carburetor adjustments should be performed only by a knowledgeable service technician at an authorized Polaris dealer, using the proper tools, procedures and specifications. Carburetor Adjustments The frequency at which the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 121
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. WARNING Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure - 2002 Polaris Universal Snowmobile | Owners Manual - Page 122
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 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 123
system should be completely drained every two years and a fresh 50/50 or 60/40 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 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 124
MAINTENANCE General Maintenance CAUTION Most cooling systems are equipped with a filter that should be periodically inspected or replaced. If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. Surge Tank Models 1 Remove the pressure cap and fill the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 125
MAINTENANCE General Maintenance EDGE RMKs 1 Remove pressure cap and fill tank to maximum recommended mark. 2 Elevate the front of the machine. 3 Start the engine and run at a fast idle for two to three minutes. Air bubbles should come to the surface of the coolant tank. Run the machine until air - 2002 Polaris Universal Snowmobile | Owners Manual - Page 126
MAINTENANCE General Maintenance Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Firmly depress the brake A lever and measure the clearance between the lever and handlebar grip. This distance, called brake lever reserve (A), should be no less than 1/2″ (1.3 cm). Brake pads must - 2002 Polaris Universal Snowmobile | Owners Manual - Page 127
MAINTENANCE General Maintenance Brake Components 1 4 2 5 1 3 2 1. 2. 3. 4. 5. Brake Caliper Chaincase Brake Disc Backing Plate Brake Pad Material (Replace when thickness is less than 1/16″). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance - 2002 Polaris Universal Snowmobile | Owners Manual - Page 128
MAINTENANCE General Maintenance Replenishing Brake Fluid WARNING After opening a bottle of brake fluid, discard any unused fluid. Do not store or use a partial bottle of brake fluid. The fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The boiling temperature of the brake - 2002 Polaris Universal Snowmobile | Owners Manual - Page 129
MAINTENANCE General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause a springy or spongy brake lever action. Bleeding is necessary to remove air from the system. CAUTION Brake fluid will damage decals, paint, and some plastics. Wipe up spills immediately. - 2002 Polaris Universal Snowmobile | Owners Manual - Page 130
Lever Travel WARNING Improper brake adjustment could result in brake failure and lead to serious injury or death. See your dealer for brake service. Frequently inspect the brake lever reserve. Firmly depress the brake lever and measure the clearance between the lever and the brake block. This - 2002 Polaris Universal Snowmobile | Owners Manual - Page 131
MAINTENANCE General Maintenance Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure: 1 Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6m) from a wall. 2 Measure the distance from the floor to the center of the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 132
MAINTENANCE General Maintenance NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Removing Halogen Bulbs - High/Low Beam 1 2 3 4 Pinch the ends of the spring (1) together and lift until it releases from - 2002 Polaris Universal Snowmobile | Owners Manual - Page 133
MAINTENANCE General Maintenance NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot which will shorten the life of the lamp. Removing the Side Bulbs 1 2 Disconnect terminal from back of bulb. Turn bulb assembly 1/4 turn to right and withdraw from - 2002 Polaris Universal Snowmobile | Owners Manual - Page 134
MAINTENANCE General Maintenance Periodically check the condition and tension of the drive belt, and always carry a spare belt. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. Standard Belt - 2002 Polaris Universal Snowmobile | Owners Manual - Page 135
MAINTENANCE General Maintenance Standard Belt Installation 1 Drop the drive belt over the drive clutch and pull back A the slack (A). NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so B that you can - 2002 Polaris Universal Snowmobile | Owners Manual - Page 136
MAINTENANCE General Maintenance Clutch System WARNING All clutch maintenance and repairs must be performed by an authorized Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. If you become aware of higher than normal clutch - 2002 Polaris Universal Snowmobile | Owners Manual - Page 137
are crucial to maintaining optimum performance. See your Owner's Manual Supplement for the recommended offset between the drive and driven change the shift pattern, resulting in poor performance. See your dealer for service and adjustments. NOTE: A worn belt will continue to function, but will - 2002 Polaris Universal Snowmobile | Owners Manual - Page 138
MAINTENANCE General Maintenance Clutch Center Distance See your Owner's Manual Specification Supplement for recommended center distance for your machine. If adjustment is necessary, see your dealer. Due to tolerances in belt length, it may be - 2002 Polaris Universal Snowmobile | Owners Manual - Page 139
MAINTENANCE General Maintenance Accessory Reverse Kit If you've had a reverse kit installed on your snowmobile, some maintenance will be required. Follow these recommendations: Chain Tension Maintain the proper chain tension as outlined on page 123. Oil Level Maintain the oil level between the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 140
MAINTENANCE General Maintenance Tool Kit A tool kit is included with your A B machine for emergency and routine maintenance. Included in the kit are: A. Emergency Start Strap C B. Phillips Screwdriver D C. Tubular Socket E D. Tubular Socket Handle E. Wrench F F. Shielded screwdriver (only models - 2002 Polaris Universal Snowmobile | Owners Manual - Page 141
Oil S Fuel Deicer S Winter Survival Kit S Trail Map S Owner's Manual S First Aid Kit 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. Maintenance - 2002 Polaris Universal Snowmobile | Owners Manual - Page 142
MAINTENANCE Track Maintenance Track Tension Data Suspension (See Owner's Manual Supplement for type) XTRA 12 121″ XTRA 12 133″ Weight Measurement Location Measurement none none 2″ behind kg) 10 lbs. (4.54 kg) 10 lbs. (4.54 kg) 10 lbs. (4.54 kg) Refer to your M-10 Owner's Manual Supplement 140 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 143
adjustments should be made only after the track is warmed up and limber. 1 Turn the machine off. 2 Lift the rear of the machine and safely support it off the ground. 3 Place the recommended weight or downward pressure on the track at the specified distance (see chart on page 140) ahead of - 2002 Polaris Universal Snowmobile | Owners Manual - Page 144
check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1 Safely support the rear of the machine with the track off the ground. 2 Start the engine and apply a small amount of throttle until the track turns slowly - 2002 Polaris Universal Snowmobile | Owners Manual - Page 145
Serious personal injury or death may occur. Using a hoist, safely lift and support the rear of the snowmobile off the ground. Rotate the track by hand on surfaces providing marginal lubrication between Hi-fax and track guide clips. Examples of marginal lubrication include ice without snow cover - 2002 Polaris Universal Snowmobile | Owners Manual - Page 146
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. CRC Suspension With Rack Steering All Steering Except CRC + + + + - 2002 Polaris Universal Snowmobile | Owners Manual - Page 147
MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With handlebars in straight ahead position, and - 2002 Polaris Universal Snowmobile | Owners Manual - Page 148
MAINTENANCE Steering System X 10″ 10″ Y Edge IFS Steering System X 10″ 10″ Y All other steering systems 146 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 149
abnormal wear or chipping is found. Skag Identification A. Steel ski 1. Standard skag 2. E-Z Steert skag B. Composite ski 1. Skag A 1 Skag Replacement 1 Raise and support the front of the machine so the skis are approximately 6″ (15.2 cm) from the ground. Remove the attaching nuts and pry the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 150
MAINTENANCE Suspension Maintenance Hi-Fax Wear Check Hi-fax wear by measuring thickness at several points along the rail. Replace Hi-fax when a thickness of 5/16″ (.8 cm) is reached (7/16″ on Xtra Lite models). Take the machine to your dealer for Hi-fax replacement. NOTE: Hi-fax wear patterns are - 2002 Polaris Universal Snowmobile | Owners Manual - Page 151
reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip: n Check rear idler wheel bolts for tightness. n Check rear - 2002 Polaris Universal Snowmobile | Owners Manual - Page 152
components except driven clutch shaft bushing as outlined in Master Repair Manual. See your dealer. Engine and Carburetor Protection Proper preparation must be fogged (Polaris PN 2870791). Follow the engine fogging instructions provided on the can. Always add a fuel conditioner/stabilizer or Premium - 2002 Polaris Universal Snowmobile | Owners Manual - Page 153
: 1 Transfer unused fuel from the fuel tank to an approved fuel container using a siphon pump. Do not re-use fuel after storage. 2 Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward. 3 Remove the spark plug(s). 4 Rotate - 2002 Polaris Universal Snowmobile | Owners Manual - Page 154
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. Transporting the Snowmobile Whenever the snowmobile is transported: 1 Turn the - 2002 Polaris Universal Snowmobile | Owners Manual - Page 155
MAINTENANCE Battery 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 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 156
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 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 157
MAINTENANCE Battery When your snowmobile is placed in storage for one month or more: DRemove the battery. DCharge it to the proper level. DStore it in a cool dry place. Before using the battery, take it to your dealer for testing and recharging. Batteries may freeze if not fully charged, resulting - 2002 Polaris Universal Snowmobile | Owners Manual - Page 158
- NOTES - 156 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 159
SECTION 8 - TROUBLESHOOTING Suspension Troubleshooting ...158 - 162 Belt Troubleshooting ...163 Engine Troubleshooting ...164 - 166 Section 8 is a quick reference guide to solving problems. 157 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 160
TROUBLESHOOTING Suspension Troubleshooting X-12 Problem Rear suspension bottoms too easily Solution (perform only one change at a time) -Check to be sure FRSS block is in highest position -Adjust torsion spring - 2002 Polaris Universal Snowmobile | Owners Manual - Page 161
TROUBLESHOOTING Suspension Troubleshooting X-12, 133″ Problem Rear suspension bottoms too easily Solution (perform only one change at a time) -Check to be sure FRSS block is in highest position -Adjust torsion spring - 2002 Polaris Universal Snowmobile | Owners Manual - Page 162
TROUBLESHOOTING Suspension Troubleshooting X-10 and Edge Problem Rear suspension bottoms too easily Solution (perform only one change at a time) -Increase torsion spring preload -Increase rear shock compression damping by turning screw clockwise - - 2002 Polaris Universal Snowmobile | Owners Manual - Page 163
TROUBLESHOOTING Suspension Troubleshooting EDGE RMK Problem Rear suspension bottoms too easily Solution (perform only one change at a time) -Adjust torsion spring blocks -Increase torsion spring diameter (see your dealer) -Increase rear - 2002 Polaris Universal Snowmobile | Owners Manual - Page 164
TROUBLESHOOTING Suspension Troubleshooting XTRA LITE Problem Rear suspension bottoms too easily Solution (perform only one change at a time) -Adjust torsion spring block to next higher position -Increase rear shock compression damping - 2002 Polaris Universal Snowmobile | Owners Manual - Page 165
TROUBLESHOOTING Belt Troubleshooting Belt Wear/Burn Belt Wear/Burn Diagnosis Causes Driving at low RPM Insufficient warm-up Solutions Drive at higher RPMs. Gear the machine down. Check - 2002 Polaris Universal Snowmobile | Owners Manual - Page 166
TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Erratic engine operating RPM during acceleration or load variations Probable Cause Drive clutch binding Solution -Disassemble drive - 2002 Polaris Universal Snowmobile | Owners Manual - Page 167
TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive system Probable Cause Solution Broken drive clutch -SEE YOUR DEALER. components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface - 2002 Polaris Universal Snowmobile | Owners Manual - Page 168
TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Probable Cause jet will cause seizure resulting in loss of power). SEE YOUR DEALER. This indicates a major engine problem that must be repaired before engine is run. -Change and test operation. -Check fuel filter flow. - 2002 Polaris Universal Snowmobile | Owners Manual - Page 169
- NOTES - 167 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 170
- NOTES - 168 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 171
SECTION 9 - WARRANTY Service And Warranty Information ...170 Warranty ...171 - 173 Polaris Extended Service Contract ...174 - 175 Section 9 contains specific warranty information. 169 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 172
supersede information contained in this manual. He's familiar with our policies and procedures and will be happy to assist you. When contacting us about parts, service, or warranty, always provide the following information: 1. Serial number 5. Details of trouble experienced 2. Model number 6. Length - 2002 Polaris Universal Snowmobile | Owners Manual - Page 173
COVERAGE WILL BE ALLOWED UNLESS YOUR SNOWMOBILE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your snowmobile is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. 171 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 174
for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing - 2002 Polaris Universal Snowmobile | Owners Manual - Page 175
THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will - 2002 Polaris Universal Snowmobile | Owners Manual - Page 176
be purchased within 90 days from the date of the unit's registration. DEach repair visit it subject to a $50.00 deductible. DThe Extended Service Contract applies to the first 5000 miles, or two calendar years from date of registration, whichever comes first. Tampering with the odometer shall void - 2002 Polaris Universal Snowmobile | Owners Manual - Page 177
or oil. DFailures caused due to improper adjustments, including but not limited to carburetor jetting and clutching. DFailure due to unauthorized service. DFailures due to lack of service as specified in the Owner's Manual or Polaris updates. This includes off-season storage as listed in the Owner - 2002 Polaris Universal Snowmobile | Owners Manual - Page 178
Area ...71 Engine Stop Switch ...71 Lighting Check ...71 Owner's Manual ...66 Park Brake ...69 Steering Inspection ...70 Tether Switch ...71 Throttle , Drive Belt ...132 Belt Removal, Electronic Reverse ...132 Belt Troubleshooting ...163 Belt/Wear Burn ...163 Bleeding Cooling System ...121-123 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 179
Switch ...71, 86 Engine Troubleshooting ...164-166 Exhaust System ...119 Exhaust System, Variable Exhaust . . 115 Extended Service Contract ...174-175 Features Maintenance Inspection ...99 Maintenance Log ...99-100 Maintenance Program ...96 Manual Start ...74 Mechanical Brakes ...68 Oil ...77, 83-84 - 2002 Polaris Universal Snowmobile | Owners Manual - Page 180
, ...157-168 Troubleshooting, Belt ...163 Troubleshooting, Engine ...164-166 Tune Up ...139 Variable Exhaust System ...115 Vehicle Identification Numbers ...9 Vehicle Nomenclature ...9 Warranty ...169-175 Water Pump Belt Inspection ...115 Water Trap Service ...116 Wear Strips ...63 Weight - 2002 Polaris Universal Snowmobile | Owners Manual - Page 181
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