Polaris FS Classic User manual

WARNING
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.
The engine exhaust from this product
contains chemicals known to the State
of California 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.

1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
SSnowmobiles
SAll-terrain vehicles (ATVs)
SRANGER utility vehicles
SVictory motorcycles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable 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 Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!

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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris
Industries Inc.
RIDER SELECT is a trademark of Polaris Industries Inc.
Copyright 2005 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2006 FS/FST Classic/Touring & FST Switchback Owner’s Manual P/N 9919670

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TABLE OF CONTENTS
Introduction 5...............................
This section contains helpful information for owners and drivers and
illustrates the location of important identification numbers that should
be recorded in the owner’s manual.
Safety 8.....................................
This section describes safe vehicle operation and identifies warning
decals and their locations.
Features 27..................................
This section identifies the locations of your snowmobile’s controls and
features.
The Perfect Fit 46............................
This section explains how to tailor the suspension and other features
for an optimum riding experience.
Pre-Ride Inspections 64......................
This section explains procedures that must be performed before riding.
Operation 73.................................
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance 85..............................
This section defines your role, and your dealer’s role, in your
snowmobile’s regular maintenance.
Polaris Products 133.........................
Troubleshooting 134.........................
Warranty 141................................
Maintenance Log 149.........................
Index 152....................................

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5
INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient
reference. It should remain with the snowmobile 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 at specific mileage intervals.
You 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.
Protect and preserve your right to ride by joining your local trail riding
clubs.

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INTRODUCTION
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 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.

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INTRODUCTION
Vehicle Identification Numbers
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 lost, the ignition switch
must be replaced.
Vehicle Model Number:
Tunnel VIN (L):
Engine Serial Number (on valve cover):
Key Number:
L

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SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on 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, on your vehicle or in this manual, alerts
you to the potential for injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor injury or damage to the vehicle.
CAUTION
Acaution indicates a situation that may result in damage to the
vehicle.
NOTE:
Anote will alert you to important information or instructions.

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SAFETY
Operator Safety
Follow the recommended maintenance program outlined beginning on
page 87 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 attention. DO NOT drink
alcohol or use drugs or medications before or while driving or
riding as a passenger. They will reduce your alertness and slow
your reaction time.
Snowmobiles are capable of traveling at high speeds. Use extra
caution to ensure operator safety. Make sure your snowmobile is
in excellent operating condition at all times. Always 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.

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SAFETY
Operator Safety
Stay Clear of Track
Your snowmobile is propelled by a revolving track that must be
partially exposed for proper operation.
WARNING
Serious injuries may result if
hands, feet, or clothing become
entangled in the track. Be alert
when riding, and remain properly
seated to stay clear of the track.
Never hold the snowmobile up or
stand behind it 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 adjustment, secure shields and
guards, secure the hood, and then restart the engine to check its
operation.
WARNING
Serious injury can occur if fingers or clothing contact the moving
parts of an engine. Always stop the engine before attempting
adjustments.

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SAFETY
Operator Safety
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience; 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.
WARNING
Improper riding position may reduce control and could result in
serious injury or death. Always ride in a position that allows for
control of your vehicle.
Survival Preparation
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.
For added protection, carry the following items on your snowmobile at
all times:
SSpare Drive Belt SExtra Set of Spark Plugs
STow Rope SExtra Oil
SFuel Deicer SWinter Survival Kit
STrail Map SOwner’s Manual
SFirst Aid Kit STool Kit

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SAFETY
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 serious injury.
Always wear an
approved helmet and
eye protection.
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.
Cargo Overload (Touring)
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.

13
SAFETY
Operator Safety
Rider Capacity
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 models indicates that the vehicle
is designed for one operator and one passenger only.
WARNING
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.
Snowmobiles designed for two riders should never be operated with
more than two people on board. When traveling with a passenger, it’s
the driver’s responsibility to operate the snowmobile safely.
Slow down! Control becomes more difficult with two people on board.
More space is required to make turns, and longer distances are
necessary for stopping.

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SAFETY
Operator Safety
Excessive Speed
WARNING
High speed driving, especially at night, could result in serious
injury or death. Always reduce speed when driving at night or in
inclement weather.
Always observe all state and local laws governing snowmobile
operation and speed limits. Always be alert and pay attention to the
trail ahead. Multiplying speed (MPH) by 1.5 will equal the
approximate number of feet per second your snowmobile travels. If
your speed is 40 MPH, your snowmobile is traveling about 60 feet per
second. If you look back for only two seconds, your snowmobile will
travel about 120 feet. If your speed is 60 MPH, your snowmobile 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 snowmobile to a stop in the distance
illuminated by the headlight.

15
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 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.
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. Avoid travelling 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 sponsored by local or state organizations.

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SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly
trained and equipped before traveling in
mountainous terrain:
STake an avalanche class
STravel with experienced people
STravel on designated trails
SMake sure each person is equipped with
a shovel, probe and avalanche beacon.
You don’t have to be snowmobiling on a slope for an avalanche to
occur. Be aware that all of the snow is connected. You may be riding
on a flat slope or snow covered road, but if the snowpack above is
unstable enough you can trigger an avalanche on a steeper slope above
you. Always be aware of snow conditions above you as you travel in
mountainous terrain.
Before riding in mountainous terrain, call or log on to your local
avalanche advisory to get current weather and snow stability
information.
For more information about avalanche training and avalanche
conditions, contact local law enforcement in your area, or visit either
the American Avalanche Association online at
www.americanavalancheassociation.org or the U.S. Forest Service
National Avalanche Center at www.avalanche.org.

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SAFETY
Operator Safety
Ice and Snow Build-up
WARNING
Ice and snow build-up may interfere with the steering of your
snowmobile, 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 is encountered, remove ice and snow build-up that may be
obstructing the steering linkage.
NOTE: If your snowmobile is equipped with RIDER SELECT,
perform this check in both the full up and full down steering
positions.
Driving Downhill
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.
WARNING
When driving on long downhill stretches, pump the brakes.
Riding the brakes may cause the brake system to overheat,
which may result in brake failure.
Excessive or repetitive use of the brakes for high speed stops will
also cause an overheated brake system. This condition may lead
to a sudden loss of brakes and/or fire and may result in serious
injury or death.