Polaris 2002 Snowmobile User manual

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 contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
PROPOSITION 65
WARNING
Snowmobile engines discharge fuel
and exhaust, which contain chemicals
known to the State of California to
cause cancer and birth defects or other
reproductive harm, onto the snow on
which they operate. Keep this engine
properly tuned and avoid unnecessary
idling and spillage during fueling.

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What’s the hottest thing on snow?
Our new web site. It’s designed just for YOU!
STechnical tips
SNew product introductions
SEvent schedules
SParts and Service Manual information
SExciting details about The Way Out
Check it out...
www.polarisindustries.com/owner

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-NOTES-

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WELCOME
Thank you for purchasing a Polaris snowmobile, and welcome to our
world-wide family of Polaris enthusiasts. Polaris proudly produces an
exciting line of recreational products, including snowmobiles,
all-terrain vehicles, personal watercraft, utility vehicles, and Victory
motorcycles.
We believe Polaris sets the standard of excellence for all snowmobiles
manufactured in the world today. Many years of experience in
engineering, design, and development have gone into making your
Polaris snowmobile the finest machine 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 Certified MSD (Master Service Dealer) Technician.
Your Polaris snowmobile dealer knows your vehicle best and is
interested in your complete satisfaction. Return to your dealership for
all of your service needs during, and after, the warranty period.
Polaris also takes great pride in our PAA (Parts Apparel and
Accessories) which are available on our online store
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
Polaris and Polaris The Way Out are registered trademarks of Polaris
Industries Inc.
Copyright 2003
Polaris Industries Inc.
All Rights Reserved
Printed in the U.S.A.

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TABLE OF CONTENTS
Section 1 - How to Use This Manual 5 - 9.......
This section contains helpful information for owners and drivers and
illustrates the location of important identification numbers that should
be recorded in your Owner’s Manual.
Section 2 - Safety 11 - 34.....................
This section describes safe vehicle operation and identifies warning
decals and their locations.
Section 3 - Features and Controls 36 - 41......
This section illustrates the locations of your snowmobile’s controls and
features.
Section 4 - The Perfect Fit 43 - 63..............
This section explains how to tailor the suspension and other features
for an optimum riding experience.
Section 5 - Getting Ready to Ride 65 - 71.......
This section explains procedures that must be performed before riding.
Section 6 - Operation 73 - 93..................
This section explains proper engine break-in, operation of features, and
operating procedures.
Section 7 - Maintenance 95 - 155..............
This section defines your role, and your dealer’s role, in your
snowmobile’s regular maintenance.
Section 8 - Troubleshooting 157 - 166..........
This section is a quick reference guide to solving problems.
Section 9 - Warranty 170 - 175.................
This section contains specific warranty information.

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SECTION 1 - HOW TO USE THIS MANUAL
Important Notes for Drivers 6.................
Preservation Of The Environment 7 - 8........
Vehicle Identification 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.

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HOW TO USE THIS MANUAL
Important Notes For Owners And Drivers
nAfter reading this manual, store it in the snowmobile for
convenient reference. It should remain with the snowmobile when
sold.
nThis manual contains the latest information at the time of printing.
We reserve the right to make product changes and improvements
without notice.
nThe illustrations and photos used in this manual are general
representations. Your model may differ.
nFollow the maintenance program outlined in this manual.
Preventive maintenance ensures that critical components of the
snowmobile are inspected by your dealer at specific mileage
intervals.
nYou and your dealer must complete the registration form included
with your snowmobile and forward it to us. This completed
form is necessary to ensure warranty coverage.
nProtect and preserve your right to ride by joining your local trail
riding clubs.

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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 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.
Air Pollution
Polaris engineers continuously investigate ways to reduce emission
levels of two-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.

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HOW TO USE THIS MANUAL
Preservation Of The Environment
Polaris is committed to supporting an environmental education
campaign. We encourage state and provincial governments across the
snowbelt to adopt rigorous safety training programs that encourage
protection of our environment, including wildlife and vegetation.
Snowmobile clubs and other organizations are working together to
protect our environment. Please support their efforts and do your part
to preserve and protect our environment.
Respect your snowmobile;
respect your environment;
and you will earn
the respect of everyone.

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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 front side of engine crankcase)
Remove the spare key and store it in a safe place. Your key can be
duplicated only by obtaining a key blank from Polaris and mating it
with your existing key.
The VIN and engine serial numbers are necessary for model
identification when registering your vehicle and obtaining insurance,
or when replacement parts are required. If your snowmobile is stolen,
these numbers are essential to its recovery and identification.
Dealer Imprint

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-NOTES-

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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.

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SAFETY
Operator Safety
The following two pages identify signal words and symbols that appear
in this manual. Your safety is involved when these words and symbols
are used. 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.
Indicates a potential hazard that could result in serious injury or
death.
Indicates a potential hazard that may result in minor personal
injury or damage to the machine.
WARNING
CAUTION
NOTE
“NOTE:” will alert you to important information or instructions.
Indicates a situation that may result in damage to the machine.
IMPORTANT
“IMPORTANT:” will alert you to important information or instructions.
CAUTION

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SAFETY
Operator Safety
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 under the
influence of drugs.
Polaris produces high performance snowmobiles capable of traveling at
high speeds. Extra caution must be observed to ensure operator safety.
Make sure your snowmobile is in excellent operating condition at all
times. We strongly recommend that the operator check major and vital
safety components before every ride.
All Polaris snowmobiles are designed and tested to provide safe
operation when used as directed. Failure of critical machine
components may result from operation with any modifications,
especially those that increase speed or power. DO NOT MODIFY
YOUR MACHINE. The snowmobile may become aerodynamically
unstable at speeds higher than those for which it is designed. Loss of
control may occur at higher speeds. Modifications may also create a
safety hazard and lead to bodily injury.
The warranty on your entire machine is terminated if any equipment
has been added, or any modifications have been made, to increase the
speed or power of the snowmobile.
WARNING

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SAFETY
Operator Safety
Stay Away From Moving Parts
Never hold the snowmobile up or stand
behind it while 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.
WARNING
Be alert when riding, and remain properly seated to stay clear of the
track. Your snowmobile is propelled by a revolving track that must be
partially exposed for proper operation. Serious injuries may result if
hands, feet, or clothing become entangled in the track.
Stop the engine before attempting adjustments. If contact is
made with fingers or clothing, the moving parts of an engine
can cause serious injury.
WARNING
Never attempt adjustments with the engine running. Turn off the
ignition, raise the hood, make the adjustment, secure shields and
guards, secure the hood, and then restart the engine to check its
operation.

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SAFETY
Operator Safety
Be Seated and in Position to Control the Vehicle
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.
WARNING
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary from person to person as each becomes more
skilled; but under most conditions, the proper position is to be seated
with feet on the running boards, and comfortably positioned for proper
throttle, brake, and steering control.
Use of a backrest may hinder your weight shifting ability. This
could affect your ability to control this rider-active vehicle in
certain extreme driving situations.
WARNING
Be Prepared for the Unexpected
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.

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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.
Always Wear Clothing Designed for Snowmobiling
Be aware of the weather forecast and especially the wind chill. A table
is provided on page 26 for your reference. To better enjoy your ride,
be prepared, warm, and comfortable.
Control becomes more difficult with two people on board. More
space is required to make turns, and longer distances are needed
for stopping. Make sure the passenger remains seated behind the
driver, facing forward, with both feet placed firmly on the running
boards. Slow down and avoid “jumping” your snowmobile.
WARNING
Loose clothing or long scarves may
easily become entangled in moving
parts and cause serious personal injury.
Always wear an approved helmet and
eye protection.
WARNING

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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 Machine
and Your Skills as a Driver
High speed driving, especially at night, is dangerous and unwise
and could result in serious personal injury or death.
WARNING
Observe all state and local laws governing snowmobile operation.
They’ve been established for your protection.
Always be alert and pay attention to the trail ahead of you.
Multiplying speed (MPH) by 1.5 will equal the approximate number of
feet per second your machine travels. If your speed is 40 MPH, your
machine is traveling about 60 feet per second. If you look back for
only two seconds, your machine will travel about 120 feet. If your
speed is 60 MPH, your machine will travel about 180 feet in two
seconds.
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 machine to a stop in the distance
illuminated by the headlight.

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SAFETY
Operator Safety
Know the Limitations of the Machine
and Your Skills as a Driver
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 machine will drown out
the sound of approaching vehicles. 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. Always check with local
residents or authorities for general information on conditions when
traveling on lakes and streams that are strange to you. Before riding
your machine on a frozen body of water, be sure the ice is thick enough
to support the machine and its operator, as well as the force created by
a moving vehicle. You may drown if you and the snowmobile break
through the ice.
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 sponsored by local or state organizations.