2025 ProStar S4 Titan Owner’s Manual

One of the most publicized issues about snowmobiles is noise. The Society of Automotive Engineers (SAE®), the standard-setting body for snowmobile development, recommends that snowmobiles conform to prescribed sound levels.

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

POLARIS engineers continuously investigate ways to reduce emission levels of four-stroke engines. We expect our efforts to lead to the reduction of potential air pollution.

In addition to our technological research, we encourage government agencies, manufacturers, distributors, dealers, ecologists, and other interested parties to work together to develop data on environmental topics.

The ignition keys are etched with an identification number. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank using the same identification number with one of your existing keys, so if both keys are lost, the ignition switch assembly must be replaced.

Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Do not stand on the plastic flap.

Never attempt adjustments with the engine running. Turn off the ignition, open the side panels or hood, make the adjustment, secure shields and guards, secure the side panels and hood, and then restart the engine to check its operation.

Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmobiles, but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.

This snowmobile is designed for two riders and includes a passenger seat. Never carry more than one passenger on this snowmobile.

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

Always carry the owner’s manual on your snowmobile. For added protection, purchase and carry the following items on your snowmobile as well:

• Spare Drive Belt

• Extra Set of Spark Plugs

• Tow Rope

• Fuel Deicer

• Winter Survival Kit

• Trail Map

• First Aid Kit

• Tool Kit

Always observe all state and local laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling about 60 feet (18 m) per second. If you look back for only two seconds, your snowmobile will travel about 120 feet (36 m). If your speed is 60 MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in two seconds.

Traveling at night requires extra caution. Check headlight and taillight to ensure proper operation, and don’t over-drive your headlight beam. Always be able to bring your snowmobile to a stop in the distance illuminated by the headlight.

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 wires on utility poles are also difficult to distinguish.

Make sure the way is clear before crossing railroads and other roads and highways. The noise of your snowmobile will drown out the sound of approaching vehicles and bare roads limit the effectiveness of the steering system. Look ahead, behind, and to both sides before turning or crossing railroad tracks or highways. Steep embankments may also hide your view. Always leave yourself a way out.

Variances in snow depth and/or water currents may result in uneven ice thickness. You may drown if you break through the ice. Never travel on frozen bodies of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the snowmobile, you and your cargo, together with any other vehicles in your party. Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Snowmobile operators assume all risk associated with ice conditions on frozen bodies of water.

When teaching inexperienced operators to ride, set up a predetermined course for practice. Make sure they know how to drive and control the snowmobile before allowing them to make longer trips. Teach them proper snowmobile courtesy, and enroll them in driver's training and safety courses.

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.

Mountainous terrain operation, even for experienced riders, can present conditions and situations that could result in serious injury or death. Please review all of the information about riding in mountainous terrain on the following pages of this manual.

The avalanche information provided in this manual should be considered basic information and is not intended to replace your participation in an avalanche safety training course. After reviewing the avalanche information in this manual, be sure to participate in an avalanche safety training course before riding in mountainous terrain. The training course will provide more information as well as the opportunity to practice riding and using proper search and recovery techniques.

For more information, education, training courses, and links to additional resources, visit:

• www.avalanche.org for North American riders.

• www.avalanche.ca for Canadian riders.

• www.lavinprognoser.se for Swedish riders.

• www.avalanches.org for European riders.

Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.

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.

If the snowmobile becomes stuck in snow, clear the running board area of snow, then step down the snow in front of the snowmobile so that when the throttle is opened, the snowmobile will be able to climb up and over the snow.

Always be aware of surroundings and terrain when riding your snowmobile. Hazardous obstructions may be hidden beneath the snow. Reduce speed and use extra caution whenever riding off established trails. Striking a hidden obstacle could cause loss of control of your vehicle and lead to severe injury or death. Remain on established trails whenever possible to reduce exposure to hazards.

When riding downhill, shift your weight to the rear of the snowmobile 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 snowmobile and keep it from rolling freely downhill.

Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you must cross the face of a slope, keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible roll-over.

Slow down when reaching the crest of a hill. Be prepared to react to obstacles, sharp drops or other people or vehicles that may be on the other side of the hill.

If you're unable to continue up a hill, turn the snowmobile downhill before it loses momentum. If this isn't possible, spin the track just enough to dig in to prevent it from rolling back down the hill. Stop the engine and set the temporary brake lock (if equipped). Keeping away from the downhill side of the snowmobile, pull the rear of the snowmobile around and point the front end and skis downhill. Remount the snowmobile, restart the engine, release the temporary brake lock, and descend the hill carefully.

Do not operate the engine with the drive belt removed.

Any servicing that requires operation without a belt can be performed by your authorized POLARIS dealer.

Do not operate the engine with the intake silencer or filter removed.

Do not attempt to service the clutches.

All clutch service can be performed by your authorized POLARIS dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.

Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from ice and snow before attempting to drive. Apply the throttle with enough authority to put the snowmobile into motion, but always operate within safety limits.

On 2-up machines, always operate with respect for a passenger.

While much control and maneuverability is achieved through the steering system and skis, maximum control is achieved by the shifting of your body weight. Maneuverability will change based on rider weight and foot position on running boards.

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 snowmobile and with what it will and won't do under various conditions. Even seasoned drivers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.

• A snowmobile depends on the rider's body position for proper balance in executing turns, traversing hills, etc. Always start on a smooth, level area to begin building your operating experience.

• Before allowing someone else to use your snowmobile, know the extent of their operating skills. Check to see if they've taken a snowmobile safety course and have an operator's certificate. For their protection, as well as yours, make sure they take a snowmobile safety course. Everyone can benefit from the course.

• Don't “jump” your snowmobile over large drifts or similar terrain. Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground. The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions. Your snowmobile is not intended for this kind of use.

• Be courteous to oncoming traffic by dimming your headlights and reducing your speed.

• When traveling in a group of snowmobiles, don't tailgate (follow too closely). Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris. Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions. Be aware of any snowmobile traffic around your vehicle. Drive defensively to avoid accidents.

• Remove the key from the ignition when you leave the snowmobile unattended.

The following information is provided to help you determine when temperatures become dangerous for riding.

WARNING

• Read owner’s manual.

• Moving parts can crush and cut.

• Keep hands clear.

• Do not operate with guards or side panels removed.

Part Number: 7300297

WARNING

Hot Surface. DO NOT touch. Burns may result.

Part Number: 7300117

WARNING

This snowmobile is designed for one (1) operator and as many passengers as there are seats with handgrips installed on the snowmobile.

• Read and understand all warnings and Owner’s Manual before operation.

• Never consume alcohol or drugs before or while operating this vehicle.

• Sharp turns could destabilize vehicle.

• Always wear DOT approved helmet and proper riding gear while operating this vehicle.

• Set parking brake before removing key from ignition.

• Do not attempt adjustment with engine running.

Part Number: 7300286.

WARNING

For proper seat installation, read and understand all warnings in Owner’s Manual.

Part Number: 7188336.

• 1 Brake Lever

• 2 Temporary Brake Lock

• 3 Instrument Cluster

• 4 Ignition Switch

• 5 Engine Stop Switch

• 6 Throttle Control

• 7 Gear Shift

• 8 Handlebar Grip Warmer

• 9 Thumb Warmer Switch

• 10 Reverse Override Switch

• 11 MODE/SET Gauge Switch

• 12 Headlight Dimmer Switch

High gear is the primary driving range for your snowmobile. Low gear is intended for use during high load, slow speed operation such as: towing, operation in hilly terrain, or extended slow speed operation. Using high gear for high load, slow speed operation can increase the chance of drive belt slippage and/or failure.

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

• H: High

• L: Low

• N: Neutral

• R: Reverse

The ignition switch has three positions: OFF, RUN, and START.

• 1 OFF Vehicle / PIDD power off

• 2 RUN Vehicle / PIDD power on

• 3 START Activates starter motor

Some rider accessories require the use of an RCA power adapter. If your model is not equipped with an RCA power plug on the handlebar cover, an accessory 12-volt RCA adapter or RCA power plug can be purchased from your POLARIS dealer.

The RCA adapter can be used if your model is equipped with the 12-volt DC power receptacle. Plug the adapter into the receptacle to convert it to a 12-volt RCA power outlet.

12-Volt RCA Power Plug

The RCA power plug (with cover) mounts to the handlebar cover and is plugged into the main vehicle wire harness. Installation instructions are provided with the accessory. This power point is powered by the load shed relay and is not fuse protected. POLARIS recommends using this power point for electric helmet shields.

The headlight can be adjusted for vertical aim using the following procedure.

1. In a well-ventilated area, position the snowmobile on a level surface with the headlight approximately 25 ft (7.6 m) from a wall 1.

2. Place the rider or the approximate weight of the rider on the seat or tunnel floorboards.

3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

4. Start the engine. Move the headlight switch to high beam.

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

6. If adjustment is necessary, access the headlight adjuster knob through the left side panel. Turn the adjuster knob clockwise to lower the beam. Turn the adjuster counter-clockwise to raise the beam.

This snowmobile is equipped with a 120 volt block heater. Use the factory-installed block heater to maintain engine coolant viscosity, prolong the life of your engine, and aid engine turnover in temperatures below 5 f (-15 c).

To gain access to the block heater, remove the left side panel and insert the block heater plug into a grounded electrical socket. For optimum performance and energy savings, plug in the block heater at least 1 hour prior to vehicle use.

The following tools are provided with the snowmobile.

• Tool Kit Pouch

  • Torx Wrench, T-30

  • 5/8 in Spark Plug Wrench, T-30

• Driven Clutch L-Wrench

• Spare Belt Holder

L-Wrench

The L-wrench 2 is used to open and close the driven clutch when working with the drive belt. To retrieve the L-wrench, rotate it counterclockwise and slide it upward from the bracket. When not in use, slide the L-wrench down into the bracket and rotate clockwise until it snaps securely into the housing.

Some models are equipped with rail scratchers to help prevent overheating when riding on ice or hard-packed snow.

This engine feature causes the ECU to shut down the engine when coolant temperature reaches 181° F (83° C) and there is no throttle lever input for 15 minutes.

The ECU monitors the vehicle speed supplied by the vehicle speed sensor. The sensor is mounted to the transmission behind the brake disc.

When the brake is applied for one second or longer, throttle application will reduce dramatically and will not increase until all pressure on the brake is released.

The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine temperature, and a diagnostic display mode.

Setting changes must be made with the engine running or with the vehicle powered by an external DC power supply connector. The information center is set to display standard units of measurement for distance and temperature.

1 Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed.

2 Speed Display - The speed display area displays either vehicle speed or engine speed.

3 Fuel Gauge - Not available on all models. The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

4 Odometer/Engine Hour Display - This area displays the odometer, Trip A, Trip B and engine hours.

Flashing indicators indicate continued operation could result in serious engine damage. The engine management system will automatically reduce engine power and create a misfire condition. Stop the engine immediately. Allow the engine to cool down.

If the engine is overheating, promptly take action to cool the engine.

• Drive in loose snow.

• Stop the engine and allow it to cool down.

• View the coolant level. Do not open the pressure cap while the engine is hot.

• Add coolant if the level is low. Do not add coolant while the engine is hot. Wait for the engine to cool before adding coolant.

• If snowmobile is equipped with rail scratchers, make sure they are deployed.

Read the Owner's Manual completely and refer to it often. The manual is your guide to a safe and enjoyable snowmobiling experience.

The throttle lever 1 and brake are the primary controls of your snowmobile. Always make sure both are functioning properly.

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

Always check the following items for proper operation before starting the engine.

Use the temporary brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less.

• 1 Brake Lever

• 2 Temporary Brake Lever Lock

• 3 Master Cylinder Reservoir/Cover

Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.

Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty.

Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting.

Make sure the engine stops when the ignition switch is turned to OFF.

If your snowmobile has a tether switch, remove the tether from the switch to make sure the engine stops immediately.

Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating.

Adjust the mirrors so they can be used to their full advantage.

Before driving away, check your surroundings. Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile.

If the rider stops the engine by pushing the engine stop switch down, restart the engine using the normal starting procedure. If the engine fails to start using the normal procedure:

1. Push the engine stop switch down to the OFF position.

2. Turn the key to the OFF position.

3. Reset the engine stop switch.

4. Turn key to the ON position. Wait for the fuel pump to stop running.

5. Crank the engine up to 10 seconds.

6. If engine fails to start, repeat steps 1-5.

If you use non-ethanol fuel (sometimes labeled “non-oxygenated”), POLARIS recommends the regular use of isopropyl-based fuel system deicer. Add 1-2 ounces per gallon (8-16 ml per liter) of gasoline to prevent damage resulting from fuel system icing. Never use deicers or additives containing methanol.

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

Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 (R+M)/2. If your snowmobile is equipped with a check engine light and it comes on, you must take your snowmobile to an authorized POLARIS 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.

Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed. POLARIS recommends that you contact an authorized POLARIS dealer, or other qualified person, to perform any service that may be necessary.

This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table section and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

Lack of lubrication will adversely affect your ride and the life of the suspension. For more information about suspension lubrication and adjustments, see your POLARIS dealer.

To check the oil level, do the following:

1. Position the snowmobile on a level surface in a well-ventilated area.

2. Start the engine. Let engine warm to an operating temperature of 173 f (78 c) or warmer.

   IMPORTANT

   Checking the oil level before the engine has reached this temperature may result in an inaccurate oil level measurement.

3. Shut off engine for 10 seconds.

4. Re-start engine and idle for 10 seconds.

5. Shut off engine.

6. Remove the left side panel.

7. Remove the dipstick 1 and wipe it dry with a clean cloth.

8. Reinstall the dipstick until fully seated.

9. Remove the dipstick and check the oil level. Oil level is in the safe range if it falls between the two marks on the dipstick 2.

10. If needed, add the recommended lubricant as needed. Do NOT overfill.

11. Reinstall and tighten the dipstick.

Always change the oil and filter according to the intervals outlined in the Polaris Maintenance Schedule on Polaris Maintenance Schedule. Replace the oil filter every time the oil is changed.

1. Park the snowmobile on level ground, put the transmission in Neutral, and engage the temporary brake lock.

2. Shut off the engine.

3. Remove the drive belt. See Drive Belt Removal for drive belt removal procedure.

4. Remove the driven clutch. See Driven Clutch Removal for driven clutch removal procedure.

1. Drain oil from the oil reservoir.

   1. Hold an oil pan under the drain plug 1.

   2. Use care to keep oil from spilling onto the clutch guard or clutches.

   3. Once oil is fully drained, re-install the oil bottle drain plug with a new washer. Torque the plug to specification.

   TORQUE

   Oil Reservoir Drain Plug

   13.27 ft-lbs (18 N·m)

2. Drain the oil from oil filter adaptor 2 by attaching an 0.5 in (13 mm) (internal diameter) hose to the adaptor spigot and route to a drain pan.

3. Using an oil filter wrench, partially loosen the oil filter by turning the filter counterclockwise. This will open the flow of oil from the housing adaptor to the drain pan.

   

4. Locate the drain plug 3 on the bottom of the crankcase. Access the crankcase drain plug through the access hole on the bulkhead. Place a drain pan below the plug.

5. Remove the drain plug and sealing washer.

6. Once oil is fully drained, re-install the drain plug with NEW washer and torque to specification.

   TORQUE

   Engine Sump Drain Plug

   13.27 ft-lbs (18 N·m)

1. When the oil filter adaptor has drained completely, remove the filter and clean the filter sealing surface with a clean, dry cloth.

2. Lubricate the O-ring on the new filter with a film of fresh engine oil. Inspect the O-ring to ensure it is in good condition.

3. Twist the new filter into place and torque to specification.

   TORQUE

   Oil Filter

   Turn by hand until filter O-ring contacts the sealing surface, then tighten an additional ¾ turn.

4. Remove the hose from the oil filter adaptor.

5. Fill the oil reservoir with the Polaris recommended engine oil.

   CAPACITY

   Recommended Engine Oil

   PS-4 Extreme 0W–50 Full Synthetic 4-Cycle Engine Oil

   Total System Capacity

   3.7 qt (3.5 l)

6. Re-attach the left side panel.

   CAUTION

   Never start the engine with the side panels removed. Running the engine with the side panel removed may cause severe injury due to moving parts.

7. Start the engine.

8. Ensure there are no leaks from the reservoir, crankcase drain plug, or oil filter.

9. Stop the engine.

10. Check the oil level. See Oil Level Check for oil level check procedure.

11. Re-install the driven clutch.

12. Re-install the drive belt. See Drive Belt Installation for belt installation procedure.

Polaris recommends the use of Polaris Extended Life 50/50 Pre-Mixed Anti-Freeze. This anti-freeze is already premixed and ready to use. Do not dilute with water. If planning to store or operate the vehicle at temperatures lower than -34 f (-37 c), greater protection may be required. An authorized POLARIS dealer can assist.

To ensure the coolant maintains its ability to protect the engine, Polaris recommends completely draining the cooling system every five (5) years and replacing with fresh Anti-freeze 50/50 Premix.

Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix.

The engine coolant level is controlled by the recovery system. The recovery system components are:

• Coolant bottle/overflow tank

• Pressure cap

• Connecting hoses

• In-bottle Thermostat

Always maintain the coolant level at or slightly above the FULL COLD mark on the coolant bottle (when the engine is cold).

1. Stop the engine and ensure engine is cold.

2. Remove the right side panel.

3. View the coolant level in the coolant bottle. Add coolant as needed.

To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added. This service must be performed when the engine is cold. Your authorized POLARIS dealer can check the coolant when performing the fall tune-up on your snowmobile.

Clutch alignment offset is important for maintaining optimum performance. Your authorized POLARIS dealer can perform service and adjustments. A special tool is required to check for proper alignment.

Periodically check the condition and tension of the drive belt. Inspect the belt for signs of excessive wear (frayed edges, missing cogs, cracks) and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting.

Always carry a spare drive belt. When placing the belt in the holder, orientate the belt to match the profile of the hood.

For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile.

1. Stop the engine after operating in a forward motion.

2. Turn the ignition key off. Wait for the engine to come to a complete stop.

3. Rotate the driven clutch counter-clockwise 1/4 turn by hand to ensure forward engagement.

4. Lock the temporary brake lock.

5. Remove the left side panel.

6. Remove the spare belt holder.

7. Retrieve the L-wrench 1. Install the wrench into the open threaded hole in the outer sheave of the clutch.

   

8. Turn the wrench clockwise until the sheaves open far enough to remove the belt.

   

9. Firmly grasp the belt 2 midway between the clutches and pull upward and rearward to remove it from the driven and then drive clutch.

   

1. Verify the driven clutch sheaves are open. If they are not, install the L-wrench and open the sheaves.

2. Drop the drive belt over the drive clutch and pull back the slack.

3. Hold the belt down between the sheaves and roll the bottom portion over the outer clutch sheave. Work the belt to the outer edge of the sheave.

4. Turn the L-wrench counterclockwise to tighten the sheaves. Work the belt around the clutches as you remove the L-wrench. Doing so will set the belt in “low gear.” The belt cord line should be flush with, or slightly above, the outer circumference of the driven clutch sheaves when finished.

   

5. Reinstall the wrench 1 to the wrench bracket to secure the fender to the console.

   

6. Install the spare belt holder.

7. Reinstall the side panel.

8. When installing a new belt, follow the belt break-in procedures.

Measure belt deflection with both clutches at rest and in their full neutral position.

Place a straight edge on the belt and apply 4 pounds of downward pressure while measuring at point. This measurement should be 1/2 inch (12.7 mm).

Belt Deflection: 0.5” (12.7mm)

1. Loosen the 7/16 in. jam nut on the belt width adjuster screw.

2. Using a 1/8 in. Allen wrench, turn the set screw inward (clockwise) to increase the distance between the sheaves (increase deflection) or outward (counter-clockwise) to decrease the distance (decrease deflection).

   

1. Using a hoist, safely lift and support the rear of the snowmobile off the ground.

2. Rotate the track by hand to check for damage.

3. Carefully examine the track along the entire length of each rod 1. Bend the track to check for breakage.

4. Replace the track if any rod damage is found.

The slide rail needs snow for lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear.

If excessive rail slide wear occurs due to poor snow conditions, additional wheel kits are available. Your authorized POLARIS dealer can provide more information.

Track damage or failure caused by operation on ice or under other poor lubrication conditions may void the track warranty.

Periodically check that the track is centered and running evenly on the slide rails 1. Misalignment will cause excessive wear to the track and slide rail.

1. Safely support the rear of the snowmobile with the track off the ground.

2. Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions. Stop the engine and let the track come to a stop (do not apply brakes).

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

4. After adjustments are complete, tighten the locknuts.

   TORQUE

   Locknuts

   35 ft-lbs (47.5 N·m)

5. Repeat steps 2–3 to verify proper alignment.

Track adjustment is critical for proper handling. Always maintain correct tension and alignment.

1. Turn the engine off.

2. Lift the rear of the snowmobile 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 the rear idler wheel.

4. Measure at the point where the weight is hanging.

5. Check for specified slack between the wear surface of the track clip and the plastic slider.

   If the track needs adjustment:

6. Loosen the rear idler shaft bolt.

7. Loosen the locknuts.

8. Tighten or loosen the track adjusting screws to provide equal adjustment on both sides of the track.

9. Repeat the measurement on the other side of the track.

   TIP

   Check more frequently when the snowmobile is new.

10. Start the engine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brakes).

11. Check track alignment (see Track Alignment) and adjust as necessary.

12. Tighten the locknuts.

13. Tighten the idler shaft bolt.

    TORQUE

    Idler Shaft Bolt

    55 ft-lbs (75 N·m)

Each week, or before a long ride, check the following items. If component damage or loose fasteners are found, your POLARIS dealer can provide service.

• 1 Ski Bolt Nuts

• 2 Tie Rod End Nuts

• 3 Upper/Lower Control Arm Nuts (All)

• 4 Sway Bar Fasteners

• 5 Shock Mounting Fasteners

• 6 Lower Control Arm Spindle Nuts

• 7 Upper Control Arm Spindle Nuts

• 8 Ski Loop Rear Fasteners

• 9 Ski Loop Front Fasteners

• 10 Ski Skag Fasteners

To align skis, do the following:

1. Place the handlebars in a straight-ahead position.

2. With only vehicle weight compressing the suspension, measure 10 in (25.4 cm) 3 forward from the center of the ski mounting bolt. From this point, measure the distance between the skis 1.

3. Measure 10 in (25.4 cm) 4 rearward from the center of the ski mounting bolt. From this point, measure the distance between the skis 2.

4. Measurement 1 should be 1/8 in (3 mm) greater than measurement 2.

Check skags before each use of the snowmobile to ensure positive steering characteristics. Skags must be replaced when worn to half their original diameter.

Polaris rail slides run along the bottom of the rail to prevent track wear. The rail slide should be inspected periodically and replaced when necessary.

For ease of inspection, all POLARIS rail slides have a wear limit indicator groove 2 to indicate the minimum permissible slide thickness 1. Replace the rail slides if they are worn to the top of the groove at any point along their length. Failure to do so may result in permanent damage to the track or rails.

It is important to properly identify the type of battery installed in your snowmobile as different battery types require different service procedures. Proper servicing and battery maintenance is crucial for battery longevity.

The four types of batteries are:

• Lead Acid Conventional

• Dry Shipped Absorbed Glass Mat (AGM)

• Lead Acid Low Maintenance

• AGM Low Maintenance

Refer to the following examples to identify the type of battery in your vehicle.

1. Lift upward on the seat latch lever 1 and remove seat.

2. Remove fasteners 2 that secure the battery box cover.

3. Remove the battery box cover 3.

4. Disconnect the black (negative) battery cable first.

5. Disconnect the red (positive) cable last.

6. Remove the battery from the battery box.

   

When installing a new battery, ensure it has a full charge prior to initial use. Using a new battery with a partial charge can damage the battery, cause shorter battery life, and hinder vehicle performance. Follow the charging instructions, included with your new battery, before installing.

To install a new battery in your snowmobile, do the following:

1. Ensure the battery is fully charged.

2. Set the battery in the battery bracket.

4. Place the battery cover on the battery bracket.

5. Secure the two battery cover screws.

6. Connect and tighten the positive (red) cable to the positive terminal first.

7. Connect and tighten the negative (black) cable to the negative terminal last.

   TORQUE

   Positive and Negative Cable

   62 in-lbs (7 N·m)

   CAUTION

   Verify the battery cables and wiring harness do not come into contact with the brake disc. Move the wiring harness/cables behind the chassis tube and away from the brake disc.

8. Route the harness ground wires 1, main battery ground cable 2, and positive (red) battery cable 3 as shown in the image. Both are routed up and over the rubber strap. If the ground wires/cable are routed down the side of the battery, they may interfere with the tab of the rear side panel. Item 4 is the constant power fuse connector.

   

9. Verify the cables are properly routed.

10. Re-install the seat. Ensure it latches securely.

To ensure your battery maintains its level of charge, the battery should be connected to a battery trickle charger using the battery charge port when not in use. The battery charge port 1 is located on the back of the seat.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 or greater using the battery charge port.

The battery provides power for only the following purposes:

• Engaging the electric starter motor to start the engine

• Powering the Polaris Interactive Digital Display (PIDD) with the ignition key when the engine is off

• Powering electrical accessories (winch, passenger seat heaters, etc.)

The engine management system turns on the battery charge relay and charges the battery only when the following conditions are met:

• The load shed relay is turned on by the engine management system

• Engine speed exceeds 2500 RPM

• Chassis DC voltage exceeds 13 volts

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

Never store a battery in a partially charged condition or hard, crystal sulfation will form on the plates resulting in reduced efficiency and shorter service life of the battery.

If you do not drive the vehicle for more than TWO weeks, maintain Absorbent Glass Mat (AGM) batteries with the BatteryMINDer® 2012 AGM - 2 AMP charger (or a similar charger).

If you plan to store the vehicle for ONE month or longer, remove the battery from the vehicle and store in a cool, dry location. Batteries will self-discharge more rapidly when stored in extreme temperatures. Continue to maintain the battery with a 2-AMP charger and inspect the battery every 60 days.