2010 Polaris 800 IQ Owners Manual

2010 Polaris 800 IQ Manual

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  • 2010 Polaris 800 IQ | Owners Manual - Page 1
  • 2010 Polaris 800 IQ | Owners Manual - Page 2
  • 2010 Polaris 800 IQ | Owners Manual - Page 3
    WARNING 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. WARNING The engine exhaust from this product
  • 2010 Polaris 800 IQ | Owners Manual - Page 4
    operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master
  • 2010 Polaris 800 IQ | Owners Manual - Page 5
    reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2010 Owner's Manual P/N 9922322 600 IQ Shift/600 IQ ES/600 LX/600 Switchback/600 Dragon Switchback 800 IQ/800 Dragon IQ/800 Switchback/800 Dragon Switchback
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    of important identification numbers that should be recorded in the owner's manual. TABLE OF CONTENTS Safety ...8 This section describes safe vehicle in your snowmobile's regular maintenance. Polaris Products...Troubleshooting ...Warranty ...Maintenance Log ...Index ... 118 119 124 133 136 3
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    4
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    when the snowmobile is sold. Some of the illustrations and photos used in this manual are general representations. Your model may differ. Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer
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    of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment. Noise Level One of the
  • 2010 Polaris 800 IQ | Owners Manual - Page 10
    Vehicle Identification Numbers INTRODUCTION Record your snowmobile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are
  • 2010 Polaris 800 IQ | Owners Manual - Page 11
    your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in
  • 2010 Polaris 800 IQ | Owners Manual - Page 12
    Operator Safety SAFETY Follow the recommended maintenance program beginning on page 79 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full
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    while warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures. Stay Clear of Engine Never attempt adjustments with the engine running. Turn off the ignition, raise the hood, make the
  • 2010 Polaris 800 IQ | Owners Manual - Page 14
    Operator Safety Riding Apparel Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 22. WARNING! Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause
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    your snowmobile at all times Spare Drive Belt Extra Set of Spark Plugs Tow Rope Extra Oil Fuel Deicer Winter Survival Kit Trail Map Owner's Manual First Aid Kit Tool Kit 12
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    Operator Safety Rider Capacity SAFETY Driving 1-Up - Some Polaris snowmobiles are designed for a single rider only. A decal on the console of these models indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders. A decal on the hood of these
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    SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy
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    Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain Take an avalanche class Travel with experienced people Travel on designated trails Make sure each person is equipped with a shovel, probe and avalanche beacon. SAFETY You
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    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
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    Operator Safety Driving Downhill SAFETY When riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the machine and keep it from rolling freely downhill.
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    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. Use extra caution when operating in hilly
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    or filter removed. Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced
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    SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile. NOTICE: Driving in too little snow will result in
  • 2010 Polaris 800 IQ | Owners Manual - Page 24
    Operator Safety SAFETY Driving Responsibly 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.
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    SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL CHART (_F) Wind Speed 40 in MPH Calm 5 10 15 20 25 30 35 40 45 50 55 60 40 36 34 32 30 29 28 28 27 26 26 25 25 Actual Thermometer
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    of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile belt guard removed. Never run engine with drive belt removed. Never service clutches yourself -- see your dealer. Pressure Cap Warning This warning
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    SAFETY Safety Decals and Locations Hot Surface Warning The hot surface warning is located near the rear of the tunnel: WARNING HOT SURFACE - DO NOT TOUCH Burn may result. Entire top of tunnel may be hot. Install only accessories specifically approved for this model by Polaris. Hot Surface Warning
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    backing up. • Avoid sharp turns. • Shift to or from reverse only when stopped. • Apply throttle slowly. NOTE: For more information, see Owner's Manual. If electric reverse: • Machine stopped and engine at idle, push yellow button on LH control to reverse. Flashing light on dash indicates reverse
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    stop. • To maintain vehicle control on ice or hard-packed surfaces, you should have a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products. • Repeated stops from high speed may cause fading or sudden loss of braking ability. • Parking brake may relax
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    FEATURES 6 5 4 10 3 11 2 1 13 12 7 8 9 Not all models are equipped with all features shown. 1. Nosepan 2. Skis 3. Front Bumper (do not use for pulling or dragging the snowmobile) 4. Hood 5. Headlight 6. Windshield 7. 8. 9. 10. 11. 12. 13. Handlebar Operator Seat Taillight Rear Bumper Snow Flap
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    FEATURES 3 4 5 2 6 7 1 Not all models are equipped with all features shown. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Fuel Filler Cap Ignition Switch MFD Gauge Engine Stop Switch Throttle Control Recoil Starter Handle Hood Hold Down Straps Parking Brake Lock Handlebar Grip Warmer Switch
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    retards timing and holds it in a retarded state. If this occurs, replace the fuel with recommended fuel or see your Polaris dealer for service. Cause of DET Activation Poor quality fuel Improper engine modifications Solution Replace with higher quality fuel Do not modify the engine Sensor Fail
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    Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator 1 2 3 4 5 6 7 8 Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage Level 3 MAX - Maximum MPH/ KPH or RPM MPH -Miles per hour KPH - Kilometers per hour
  • 2010 Polaris 800 IQ | Owners Manual - Page 34
    Instrumentation MFD Settings With the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch (+) has a MODE button (top) and a SET button (bottom). FEATURES + Standard vs. Metric The MFD will display either standard or metric units of measurement.
  • 2010 Polaris 800 IQ | Owners Manual - Page 35
    FEATURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program will remain in the display until another is selected. TIP: The analog will always display either MPH or engine RPM (whichever setting
  • 2010 Polaris 800 IQ | Owners Manual - Page 36
    Instrumentation FEATURES MFD Digital Display Programs Trip Settings Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled. 1. To reset a trip odometer to zero, enter the Trip 1 or Trip 2 display. 2. Press and hold the SET button for two seconds. If the
  • 2010 Polaris 800 IQ | Owners Manual - Page 37
    FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting 1. While in the CLOCK display, press and hold the SET button for five seconds. 2. When the hour starts flashing press the SET switch once to advance one hour, or press and hold the SET button to advance the
  • 2010 Polaris 800 IQ | Owners Manual - Page 38
    Instrumentation FEATURES MFD Digital Display Programs Engine Program The Engine Program automatically displays the engine coolant temperature, engine hours, electrical system voltage level and fuel level (if equipped). On machines equipped with altimeter sensor and ambient air temperature sensors,
  • 2010 Polaris 800 IQ | Owners Manual - Page 39
    FEATURES Instrumentation Engine Program Altitude (if equipped) MFD Digital Display Programs The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. TIP: Press and hold the MODE switch for ten seconds to switch
  • 2010 Polaris 800 IQ | Owners Manual - Page 40
    to view maximum vehicle speed, maximum engine rpm or the current service interval setting. The gauge automatically logs the maximum speed and engine Program will display the history of the Maximum Speed, Maximum RPM and Service Interval settings. Maximum Speed/RPM Reset While in either the MAX MPH
  • 2010 Polaris 800 IQ | Owners Manual - Page 41
    "ENG" will flash in the icon area for five seconds each time the vehicle is started until the service reminder is reset. To reset the reminder at the existing interval: 1. Enter the service interval screen. 2. Press and hold the SET button for ten seconds, continuing to hold even after the display
  • 2010 Polaris 800 IQ | Owners Manual - Page 42
    Instrumentation FEATURES MFD Battery Replacement (models with clocks) If the clock function of the MFD isn't working properly, replace the battery. Replacement batteries are available from your dealer. 1. Remove the plenum from the underside of the hood. 2. Locate the black battery compartment. It
  • 2010 Polaris 800 IQ | Owners Manual - Page 43
    FEATURES Instrumentation MFD Battery Replacement (models with clocks) 6. Install a new battery with fingers only. 7. Seal the end of the battery compartment using high strength doublesided tape between the two compartment halves or high strength single-sided tape around the outside of the
  • 2010 Polaris 800 IQ | Owners Manual - Page 44
    Front Suspension Adjustments Independent Front Suspension (IFS) THE PERFECT FIT Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We
  • 2010 Polaris 800 IQ | Owners Manual - Page 45
    THE PERFECT FIT Shock Spring Preload Front Suspension Adjustments Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same
  • 2010 Polaris 800 IQ | Owners Manual - Page 46
    , tool use, and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a Polaris dealer. 43
  • 2010 Polaris 800 IQ | Owners Manual - Page 47
    THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, 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. However, all suspension designs
  • 2010 Polaris 800 IQ | Owners Manual - Page 48
    Rear Suspension Adjustments Suspension Performance Tips THE PERFECT FIT • Rider weight usually determines the position at which the spring preload should be set. However, this may vary with riding style. With a little experimentation, each rider can find a preferred setup. These adjustments are
  • 2010 Polaris 800 IQ | Owners Manual - Page 49
    THE PERFECT FIT Rear Suspension Adjustments To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension. The rear bumper may need to be
  • 2010 Polaris 800 IQ | Owners Manual - Page 50
    Rear Suspension Adjustments THE PERFECT FIT Initial Spring Preload Setting (Sag Method) To determine sag, commonly referred to as ride-in, subtract measurement Y from X (sag=X-Y). If the measured sag is incorrect, adjust the FRA position and/or rear torsion spring preload. Suspension Recommended
  • 2010 Polaris 800 IQ | Owners Manual - Page 51
    THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will
  • 2010 Polaris 800 IQ | Owners Manual - Page 52
    Rear Suspension Adjustments Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter straps. Tighten the straps to increase ski pressure. Loosen
  • 2010 Polaris 800 IQ | Owners Manual - Page 53
    THE PERFECT FIT Rear Suspension Adjustments Turn the adjuster on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster one click, then test ride. • Turn the adjuster clockwise for a stiffer
  • 2010 Polaris 800 IQ | Owners Manual - Page 54
    Rear Suspension Adjustments Suspension Coupling THE PERFECT FIT On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other. Rear suspension
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    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
  • 2010 Polaris 800 IQ | Owners Manual - Page 56
    ski lift during acceleration, rotate the RRSS to a lower position. TIP: Your dealer can help you with initial setup and additional setup instructions to help you achieve your optimum ride. A scissor stop tool is also available from your dealer. THE PERFECT FIT Weight Transfer During Acceleration
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    THE PERFECT FIT Handlebar Position Handlebar Adjustments 1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver. 2. Adjust the handlebar forward or rearward to the desired position. 3. Tighten the bolts. Loosen top bolts to adjust
  • 2010 Polaris 800 IQ | Owners Manual - Page 58
    : brakes, clutches, fuel systems, and exhaust systems. Exhaust systems are critical safety areas that must use approved Polaris parts. Please see your Polaris dealer for service. 55
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    THE PERFECT FIT Traction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from
  • 2010 Polaris 800 IQ | Owners Manual - Page 60
    Traction Products nCarbide Skags THE PERFECT FIT A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle
  • 2010 Polaris 800 IQ | Owners Manual - Page 61
    PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Item Drive Belt
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    and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable lever freeplay, DO NOT start the engine. Have the throttle serviced immediately. n Throttle Safety Switch Test the throttle safety switch system before
  • 2010 Polaris 800 IQ | Owners Manual - Page 63
    indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 98 or see your dealer for service. 1/2I (1.3 cm) Lever Feel If the brake lever feels "spongy" when squeezed, check the brake fluid level and condition. Add fluid as needed. See page
  • 2010 Polaris 800 IQ | Owners Manual - Page 64
    is in use. If the parking brake light does not come on when the parking brake or service brake is in use, have it serviced by your dealer. Lock Release To release the lock, squeeze the brake lever tightly. The lock will return to the unlocked position. WARNING! If the
  • 2010 Polaris 800 IQ | Owners Manual - Page 65
    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
  • 2010 Polaris 800 IQ | Owners Manual - Page 66
    Before Starting the Engine n Hood Latches PRE-RIDE INSPECTIONS The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure
  • 2010 Polaris 800 IQ | Owners Manual - Page 67
    PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See
  • 2010 Polaris 800 IQ | Owners Manual - Page 68
    Starting the Engine OPERATION NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the key to the ON position. 2. Pull the engine stop switch up to
  • 2010 Polaris 800 IQ | Owners Manual - Page 69
    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 fuel with one pint of Polaris injection oil
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    Engine Break-In OPERATION Oil Injection System Always check and fill the oil tank when refueling. See page 71. NOTICE: Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn't go down, contact your dealer
  • 2010 Polaris 800 IQ | Owners Manual - Page 71
    behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear support. WARNING! Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure. This could cause loss
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    Fuel WARNING OPERATION Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel outdoors or in a well-ventilated area. Always turn off the engine before refueling. Do not overfill the tank. Do not fill the tank
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    OPERATION Fuel Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85). NOTICE: Operating
  • 2010 Polaris 800 IQ | Owners Manual - Page 74
    n Oil Low Oil Indicator Light OPERATION The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 67 for oil recommendations. Low Oil Level Maintaining the proper oil level will
  • 2010 Polaris 800 IQ | Owners Manual - Page 75
    OPERATION n Engine Stop Switch Push down on the engine stop switch (+) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. + n Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is
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    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
  • 2010 Polaris 800 IQ | Owners Manual - Page 77
    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 72 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Engine Stop Switch Throttle Safety Switch Tether Switch (
  • 2010 Polaris 800 IQ | Owners Manual - Page 78
    Electronic Reverse (PERCt) WARNING OPERATION Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed. • Shift to or
  • 2010 Polaris 800 IQ | Owners Manual - Page 79
    OPERATION Electronic Reverse (PERCt) 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 reverse button on the left-hand control for one second, then release. The engine will automatically reduce RPM and start a
  • 2010 Polaris 800 IQ | Owners Manual - Page 80
    Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4I (10 cm) off the ground. Remove the key and
  • 2010 Polaris 800 IQ | Owners Manual - Page 81
    and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups
  • 2010 Polaris 800 IQ | Owners Manual - Page 82
    Polaris Recommended Maintenance Program MAINTENANCE To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 133. The
  • 2010 Polaris 800 IQ | Owners Manual - Page 83
    MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use
  • 2010 Polaris 800 IQ | Owners Manual - Page 84
    Periodic Maintenance Interval Table Item See Page 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) MAINTENANCE 2000 mi. (3200 km) PreSeason Frequency BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake Fluid Idle RPM Throttle Lever Oil Pump
  • 2010 Polaris 800 IQ | Owners Manual - Page 85
    MAINTENANCE Item Periodic Maintenance Interval Table See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason CHASSIS Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Suspension Shock Oil Cooling Fins and Shroud
  • 2010 Polaris 800 IQ | Owners Manual - Page 86
    Lubrication MAINTENANCE Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 79 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles
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    MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. + Throttle Cable Lubricate the throttle cable
  • 2010 Polaris 800 IQ | Owners Manual - Page 88
    Lubrication MAINTENANCE n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 79. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). Change
  • 2010 Polaris 800 IQ | Owners Manual - Page 89
    MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4) and drain the oil into a drain pan. Allow the oil to drain completely. 4 3. Clean off all metal shavings from the plug. 4. Install a new sealing washer on the drain plug. The
  • 2010 Polaris 800 IQ | Owners Manual - Page 90
    fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your machine. Change the spark plugs every 2000-2500 miles (3200-4000 km Use
  • 2010 Polaris 800 IQ | Owners Manual - Page 91
    be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. TIP: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetor/throttle
  • 2010 Polaris 800 IQ | Owners Manual - Page 92
    Spark Plug Removal and Replacement 1. Remove the spark plug cap. 2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plug installation. 4. Torque to 18-22 ft. lbs. (24-30 Nm). 5. Reinstall the spark plug cap.
  • 2010 Polaris 800 IQ | Owners Manual - Page 93
    carburetor malfunction. Always reinstall the intake filters before operating the snowmobile. Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump. Fuel Filter/Fuel Lines See your Polaris dealer for replacement of the fuel filter
  • 2010 Polaris 800 IQ | Owners Manual - Page 94
    Cooling System Coolant MAINTENANCE The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or operated at extremely low temperatures, greater
  • 2010 Polaris 800 IQ | Owners Manual - Page 95
    coolant maintains its ability to protect the engine, drain the system completely every two years and add a fresh mixture of antifreeze and distilled water. This service must be performed when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your
  • 2010 Polaris 800 IQ | Owners Manual - Page 96
    Cooling System MAINTENANCE Bleeding the Cooling System CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly
  • 2010 Polaris 800 IQ | Owners Manual - Page 97
    the engine running. 1. Open the hood and inspect the muffler and pipes for cracks or damage. 2. Check for weak or missing retaining springs or damper/support grommets. 3. Check for loose clamps on the pipe covers. 94
  • 2010 Polaris 800 IQ | Owners Manual - Page 98
    Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. Loosen the
  • 2010 Polaris 800 IQ | Owners Manual - Page 99
    MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 60. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16I). A kit is available for replacing brake pads. See your
  • 2010 Polaris 800 IQ | Owners Manual - Page 100
    Brakes MAINTENANCE Brake Fluid WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to
  • 2010 Polaris 800 IQ | Owners Manual - Page 101
    MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and
  • 2010 Polaris 800 IQ | Owners Manual - Page 102
    Lights MAINTENANCE 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. If fingers do touch the bulb, clean it with an alcohol-moistened towel. Headlight Bulb Removal 1. Remove the plenum covering from the
  • 2010 Polaris 800 IQ | Owners Manual - Page 103
    MAINTENANCE Lights Taillight/Brakelight Replacement 1. Remove the screws securing the taillight lens. Remove the lens. 2. Push the bulb inward and turn it counterclockwise to remove it. 3. Install a new bulb. Push the bulb inward and turn it clockwise to secure it. 4. Reinstall the taillight lens.
  • 2010 Polaris 800 IQ | Owners Manual - Page 104
    alignment offset is important for maintaining optimum performance. See your dealer for service and adjustments. A special tool is required to check for proper alignment. Clutch Center Distance See your Owner's Manual Supplement for recommended center distance for your machine. If adjustment is
  • 2010 Polaris 800 IQ | Owners Manual - Page 105
    signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 123. Always carry a spare drive belt for emergency use. Store the spare belt on top of the electrical box, which is mounted
  • 2010 Polaris 800 IQ | Owners Manual - Page 106
    Clutch System MAINTENANCE 1 2 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 apply downward pressure while measuring at point 2. This measurement should be 1 1/4I (3.2 cm). Drive Belt
  • 2010 Polaris 800 IQ | Owners Manual - Page 107
    MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure
  • 2010 Polaris 800 IQ | Owners Manual - Page 108
    Clutch System MAINTENANCE Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. 2. To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them. If
  • 2010 Polaris 800 IQ | Owners Manual - Page 109
    MAINTENANCE Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Matte Clear Coat Cleaning Matte finish products are prone to trapping dirt, oils and
  • 2010 Polaris 800 IQ | Owners Manual - Page 110
    rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground. 2. Rotate the track by hand WARNING! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss
  • 2010 Polaris 800 IQ | Owners Manual - Page 111
    adjustments should be made only after the track is warmed up and limber. 1. Turn the engine 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) ahead of the center of
  • 2010 Polaris 800 IQ | Owners Manual - Page 112
    Track Maintenance Track Tension MAINTENANCE 5. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 108. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. Adjusting Screw
  • 2010 Polaris 800 IQ | Owners Manual - Page 113
    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
  • 2010 Polaris 800 IQ | Owners Manual - Page 114
    Steering System MAINTENANCE Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary. + + + + + 111
  • 2010 Polaris 800 IQ | Owners Manual - Page 115
    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 the handlebars in a straight ahead
  • 2010 Polaris 800 IQ | Owners Manual - Page 116
    any abnormal wear or chipping is found. Skag Replacement Some models are equipped with single skags. Some models are equipped with dual skags. 1. Raise and support the front of the machine so the skis are approximately 6I (15.2 cm) from the ground. 2. Remove the attaching nuts and pry the skag
  • 2010 Polaris 800 IQ | Owners Manual - Page 117
    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 suspension mounting bolts for tightness. n Check rear
  • 2010 Polaris 800 IQ | Owners Manual - Page 118
    Extended Storage MAINTENANCE Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 118 for the part numbers of Polaris products. Cleaning and Preservation Proper storage starts with
  • 2010 Polaris 800 IQ | Owners Manual - Page 119
    except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer. Engine Protection Proper preparation of the engine and be fogged with fogging oil. Follow the engine fogging instructions provided on the container. Always add Premium Carbon Clean or a fuel conditioner
  • 2010 Polaris 800 IQ | Owners Manual - Page 120
    suitable straps. 3. Remove the ignition key to prevent loss. 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. 117
  • 2010 Polaris 800 IQ | Owners Manual - Page 121
    POLARIS PRODUCTS Part No. 2870791 2877882 2877953 2877883 2877884 2877887 2877888 2873105 2872951 2871312 2871322 2871423 2871329 2871323 2871534 2871326 2870652 2872189 2872893 2870505 2872889 2872890 Description Engine Lubricants Fogging Oil (12 oz. Aerosol) VES Gold Plus Synthetic 2-Cycle Engine
  • 2010 Polaris 800 IQ | Owners Manual - Page 122
    Engine Troubleshooting TROUBLESHOOTING 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 Harsh drive clutch engagement Probable Cause Solution Drive clutch
  • 2010 Polaris 800 IQ | Owners Manual - Page 123
    TROUBLESHOOTING Problem Noise in drive system Engine Troubleshooting Probable Cause Solution Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain
  • 2010 Polaris 800 IQ | Owners Manual - Page 124
    Engine Troubleshooting Problem Engine turns but fails to start Faulty ignition TROUBLESHOOTING Probable Cause Solution too small will cause seizure resulting in loss of power. This indicates a major engine problem that must be repaired before operating. SEE YOUR DEALER. • Replace the plug(s). •
  • 2010 Polaris 800 IQ | Owners Manual - Page 125
    TROUBLESHOOTING Problem Rear suspension bottoms too easily Suspension Troubleshooting Solution • Adjust torsion spring preload to achieve proper static sag (see page 46). • Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear
  • 2010 Polaris 800 IQ | Owners Manual - Page 126
    Causes Driving at low RPM Insufficient warm-up TROUBLESHOOTING Belt Wear/Burn Diagnosis Solutions • Drive at higher RPMs. Gear the machine down. Check belt deflection. • Warm the engine at least five minutes. Take the
  • 2010 Polaris 800 IQ | Owners Manual - Page 127
    of purchase 5. Details of trouble experienced 6. Length of time and conditions of operation 7. Previous correspondence Use the page provided near the front of your Owner's Manual to record the identification numbers of your snowmobile and its engine. Polaris Customer Service United States: 1-888-704
  • 2010 Polaris 800 IQ | Owners Manual - Page 128
    snowmobiles in recovery of stolen machines. A. In addition to notifying the proper law enforcement officials, the owner must call Polaris Customer Service. B. Owners must provide their name, address, telephone number and the model and serial number of stolen machines. 2. 3. Polaris warranty will
  • 2010 Polaris 800 IQ | Owners Manual - Page 129
    preparation and setup of your snowmobile is very important in ensuring trouble-free operation. Purchasing a snowmobile in the crate or without any damages that occur during trailer transit or as a result of unauthorized service or parts. In addition, this warranty does not cover physical damage to
  • 2010 Polaris 800 IQ | Owners Manual - Page 130
    dealer is YOUR responsibility). Polaris recommends 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. Your dealer will contact the appropriate personnel at Polaris if
  • 2010 Polaris 800 IQ | Owners Manual - Page 131
    to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery products for lubrication and maintenance as directed by the Owner's manual is highly recommended. Should a failure occur during the warranty
  • 2010 Polaris 800 IQ | Owners Manual - Page 132
    oil. • Piston seizures, unless caused by a defective engine component. • Failures caused due to improper adjustments. • Failure due to unauthorized service. • Failures due to lack of service as required in the owner's manual or Polaris updates. This includes off-season storage as listed in the owner
  • 2010 Polaris 800 IQ | Owners Manual - Page 133
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2010 Polaris 800 IQ | Owners Manual - Page 134
    U.S.A. EPA Emissions Limited Warranty WARRANTY This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it
  • 2010 Polaris 800 IQ | Owners Manual - Page 135
    responsible for performing the scheduled maintenance identified in the owner's manual. Polaris may deny warranty claims for failures that have been recommends that you contact an authorized Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that
  • 2010 Polaris 800 IQ | Owners Manual - Page 136
    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. MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240
  • 2010 Polaris 800 IQ | Owners Manual - Page 137
    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 134
  • 2010 Polaris 800 IQ | Owners Manual - Page 138
    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 135
  • 2010 Polaris 800 IQ | Owners Manual - Page 139
    Linkage...115 Coolant...91 Coolant Level...91 Cooling System ...91-93 Cooling System, Bleeding ...93 Cooling System, Flushing ...92 Customer Service...124 E Electrical Connections ...117 Engine Break-In ...66-67 Engine Protection ...116 Engine Restarting ...65 Engine Safety ...10 Engine Starting
  • 2010 Polaris 800 IQ | Owners Manual - Page 140
    INDEX G Gauge Cleaning...40 O Oil Filter ...89 Oil Indicator Light ...71 Oil Injection System...67 Oil Level...71 Oil Lines ...89 Oil Recommendations ...67 Operating in Deep Snow ...20 Operation Warning ...25-26 Operator Safety...8-22 H Handlebar Adjustments...Handlebar Angle ...Handlebar Position
  • 2010 Polaris 800 IQ | Owners Manual - Page 141
    Warm-Up ...68 Track Warning ...24 Traction Products ...56-57 Transporting the Snowmobile ...117 Troubleshooting, Drive Belt ...123 Troubleshooting, Engine ...119-121 Troubleshooting, Suspension ...122 Tune-Up ...106 V Vehicle Identification Numbers ...5 W Wear Strips ...57 Weight Transfer ...53
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