2004 Polaris WideTrak Owners Manual
2004 Polaris WideTrak Manual
2004 Polaris WideTrak manual content summary:
- 2004 Polaris WideTrak | Owners Manual - Page 1
2004 Touring & WideTrak Snowmobiles Owner's Manual for Vehicle Maintenance and Safety - 2004 Polaris WideTrak | Owners Manual - Page 2
Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. PROPOSITION 65 WARNING Snowmobile engines discharge fuel - 2004 Polaris WideTrak | Owners Manual - Page 3
What's the hottest thing on snow? A Polaris owner's Web site, designed just for YOU! S S S S S Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out...www.polarisindustries.com/owner 1 - 2004 Polaris WideTrak | Owners Manual - Page 4
Copyright 2003 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 - 2004 Polaris WideTrak | Owners Manual - Page 5
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 - 2004 Polaris WideTrak | Owners Manual - Page 6
identification numbers that should be recorded in the owner's manual. This section describes safe vehicle operation and identifies warning ...73 Polaris Products ...126 Troubleshooting ...127 This section is a quick reference guide to solving problems. This section outlines specific warranty - 2004 Polaris WideTrak | Owners Manual - Page 7
remain with the snowmobile when sold. n The illustrations and photos used in this manual are general representations. Your model may differ. n Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your - 2004 Polaris WideTrak | Owners Manual - Page 8
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. Respect your snowmobile - 2004 Polaris WideTrak | Owners Manual - Page 9
Vehicle Identification Numbers INTRODUCTION The tunnel vehicle identification number (VIN) and engine serial number are important for model identification when registering your snowmobile, when obtaining insurance, and when ordering replacement parts. In the event your snowmobile is stolen, these - 2004 Polaris WideTrak | Owners Manual - Page 10
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 personal injury. WARNING The the vehicle. CAUTION NOTE: A note will alert you to important information or instructions. 8 - 2004 Polaris WideTrak | Owners Manual - Page 11
Operator Safety SAFETY WARNING Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it's prohibited by law to drive while intoxicated - 2004 Polaris WideTrak | Owners Manual - Page 12
warming up the track. A loose track or flying debris could cause serious personal injury or death. We recommend having your dealer perform track service and alignment procedures. Be alert when riding, and remain properly seated to stay clear of the track. Your snowmobile is propelled by a revolving - 2004 Polaris WideTrak | Owners Manual - Page 13
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 11 - 2004 Polaris WideTrak | Owners Manual - Page 14
SAFETY Operator Safety Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier. WARNING Control becomes more difficult with two people on - 2004 Polaris WideTrak | Owners Manual - Page 15
Operator Safety Excessive Speed SAFETY WARNING High speed driving, especially at night, could result in serious personal injury or death. Always reduce speed when driving at night or in inclement weather. Observe all state and local laws governing snowmobile operation. They've been established - 2004 Polaris WideTrak | Owners Manual - Page 16
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 - 2004 Polaris WideTrak | Owners Manual - Page 17
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 - 2004 Polaris WideTrak | Owners Manual - Page 18
SAFETY Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Operating in hilly terrain requires extreme - 2004 Polaris WideTrak | Owners Manual - Page 19
of the guard by removing it. It's provided for your safety. Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. Operation of the engine with the belt removed may result in personal injury or - 2004 Polaris WideTrak | Owners Manual - Page 20
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 recommended maintenance program outlined beginning on page 73 of this manual to ensure that all critical components on the snowmobile - 2004 Polaris WideTrak | Owners Manual - Page 21
Operator Safety SAFETY Powder Snow Operation Moveable hood closures are included on some Polaris snowmobiles. They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20_F), Polaris recommends closing - 2004 Polaris WideTrak | Owners Manual - Page 22
SAFETY Operator 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. - 2004 Polaris WideTrak | Owners Manual - Page 23
Operator Safety SAFETY Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART (°F) Estimated Wind Speed in MPH Actual Thermometer Reading (°F) 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60 Equivalent - 2004 Polaris WideTrak | Owners Manual - Page 24
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 with this guard open. Never run engine with drive belt removed. Never service clutches yourself - see your dealer. Air Box Warning This warning decal - 2004 Polaris WideTrak | Owners Manual - Page 25
Safety Decals and Locations Track Warning SAFETY The track warning decal is located on the rear of the tunnel: Cargo Carrier Warnings Machines with a cargo carrier have a cargo weight decal at the rear of the snowmobile. The decal specifies the maximum recommended weight capacity for the carrier. - 2004 Polaris WideTrak | Owners Manual - Page 26
SAFETY Safety Decals and Locations Standard Reverse Warning The Polaris WideTrak snowmobile is equipped with standard reverse. The reverse warning decal is located above the instrument housing. 24 - 2004 Polaris WideTrak | Owners Manual - Page 27
Safety Decals and Locations Electronic Reverse Warning Polaris snowmobiles equipped with electronic reverse will have the electronic reverse warning decal. + SAFETY WARNING AVERTISSEMENT 25 - 2004 Polaris WideTrak | Owners Manual - Page 28
SAFETY Safety Decals and Locations Operation Warning Operation warning decals are present on the console of all Polaris snowmobiles, in both French and English. WARNING Touring Models WARNING WideTrak 26 - 2004 Polaris WideTrak | Owners Manual - Page 29
Safety Decals and Locations Operation Warning AVERTISSEMENT SAFETY Touring Models AVERTISSEMENT WideTrak 27 - 2004 Polaris WideTrak | Owners Manual - Page 30
controls and special feature controls are illustrated on this page. Not all models come with all special features. Refer to your Owner's Manual Supplement for the features on your machine. 6 5 4 7 8 9 10 3 2 11 1 12 13 16 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18 - 2004 Polaris WideTrak | Owners Manual - Page 31
FEATURES 6 3 2 1 11 4 5 10 7 8 9 12 13 14 17 16 15 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Hood Headlight Windshield Handlebar Seat Backrest Storage Compartment Taillights Rear Bumper Snow Flap 11. 12. 13. 14. 15. 16. 17. 18. Passenger Hand Hold Track Suspension Trailing Arm Nosepan Front Bumper Skis - 2004 Polaris WideTrak | Owners Manual - Page 32
THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions - 2004 Polaris WideTrak | Owners Manual - Page 33
THE PERFECT FIT Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 114 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. For the best ride, the suspension should be adjusted - 2004 Polaris WideTrak | Owners Manual - Page 34
THE PERFECT FIT Front Suspension Adjustments Shock Damping Adjustments to the compression stiffness of Indy Select or RydeFX SOLO shocks can be made by turning the adjustment screw (Select) or actuator (SOLO), located near the base of the shock (A). This adjustment is the easiest to perform and it - 2004 Polaris WideTrak | Owners Manual - Page 35
THE PERFECT FIT Front Suspension Adjustments Adjusting Front Shock Spring Preload 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 - 2004 Polaris WideTrak | Owners Manual - Page 36
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. Front Springs For models without externally adjustable or revalvable - 2004 Polaris WideTrak | Owners Manual - Page 37
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 and - 2004 Polaris WideTrak | Owners Manual - Page 38
THE PERFECT FIT Edge 136 Rear Suspension Adjustments (Indy 340 Touring and Sport Touring) Initial Spring Preload Setting (Sag Method) To set up the EDGE rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement - 2004 Polaris WideTrak | Owners Manual - Page 39
THE PERFECT FIT Edge 136 Rear Suspension Adjustments (Indy 340 Touring and Sport Touring) Rear Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your - 2004 Polaris WideTrak | Owners Manual - Page 40
THE PERFECT FIT Edge 136 Rear Suspension Adjustments (Indy 340 Touring and Sport Touring) Optional Coil Springs Different rate coil springs are available for some shocks if a firmer ride is desired. Contact your dealer for more information. Suspension Coupling On all Polaris snowmobile rear - 2004 Polaris WideTrak | Owners Manual - Page 41
THE PERFECT FIT Edge 136 Rear Suspension Adjustments (Indy 340 Touring and Sport Touring) Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement - 2004 Polaris WideTrak | Owners Manual - Page 42
THE PERFECT FIT Edge 136 Rear Suspension Adjustments (Indy 340 Touring and Sport Touring) Weight Transfer During Acceleration Rear Rear Scissor Stop (RRSS) The preferred method for controlling weight transfer during acceleration of the EDGE rear suspension is by adjusting the RRSS. The RRSS is - 2004 Polaris WideTrak | Owners Manual - Page 43
Edge Touring Suspension (ETS) Adjustments Torsion Springs Two torsion springs are used on the rear arm of the ETS. Preload adjustments can be made by turning the rectangular adjusters with a spark plug wrench. The firm torsion spring should be used if frequent bottoming is encountered during two up - 2004 Polaris WideTrak | Owners Manual - Page 44
THE PERFECT FIT Edge Touring Suspension (ETS) Adjustments Initial Setup and Calibration The following information has been compiled to assist you in tuning your ETS to its maximum potential. The Ride Control Adjuster (RCA) 1. Refer to the initial setup reference chart (located under the hood of - 2004 Polaris WideTrak | Owners Manual - Page 45
. ETS ACE Settings A switch labeled "ESC" on the left-hand control assembly is used to adjust the position of the ACE module. The following instructions describe all the features programmed into the ACE module. 1. By pressing the left hand control switch up (firm) or down (soft) one time, the - 2004 Polaris WideTrak | Owners Manual - Page 46
THE PERFECT FIT ETS ACE Adjustments ETS ACE Settings IMPORTANT NOTES: The time to move one position can take up to 12 seconds depending on the rear shock loads. Due to alternator limitations, the ACE module will operate only at engine speeds above 3500 RPM. Similar to the RCA on the standard ETS, - 2004 Polaris WideTrak | Owners Manual - Page 47
WideTrak Rear Suspension Adjustments Rear Spring Settings THE PERFECT FIT Rear spring adjustment is primarily a control for riding comfort. To check for the recommended settings: 1. Lift the rear of the machine to relieve the rear springs. 2. Slowly lower the machine and measure the distance - 2004 Polaris WideTrak | Owners Manual - Page 48
THE PERFECT FIT Standard Handlebars Handlebar Adjustments Follow these steps to adjust the handlebars for a personal fit. 1. Remove the handlebar cover to A expose the handlebar and the four adjuster block bolts (A). 2. Using a 7/16″ (11 mm) wrench, loosen the four nuts on the bottom of the - 2004 Polaris WideTrak | Owners Manual - Page 49
, clutches, fuel systems, and exhaust systems. NOTE: Exhaust systems are critical safety areas that must use approved Polaris parts. Please see your Polaris dealer for service. 47 - 2004 Polaris WideTrak | Owners Manual - Page 50
THE PERFECT FIT Accessories Traction Products Another way to tailor your machine is to install traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. NOTE: Polaris - 2004 Polaris WideTrak | Owners Manual - Page 51
Accessories THE PERFECT FIT Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products. CAUTION Aggressive studding patterns may require grinding - 2004 Polaris WideTrak | Owners Manual - Page 52
. See your dealer for more information. Some models are manufactured with tunnel wear strips or wear strip coolers installed. Refer to your Owner's Manual Supplement to determine if your model has wear strips. Wear strips are designed for a specific stud length. See your dealer's studding chart for - 2004 Polaris WideTrak | Owners Manual - Page 53
to be sure of proper operation. Read and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. We've attempted to provide not function smoothly, DO NOT start the engine. Have the throttle serviced immediately. The need for a properly functioning brake is critical. - 2004 Polaris WideTrak | Owners Manual - Page 54
the fluid. Also check for the presence of air in the fluid system. Refer to page 99 for more information, or see your dealer for service. Replace brake fluid at least every two years with Polaris DOT 3 high temperature brake fluid. All DOT 3 brake fluid is not alike. Use only Polaris - 2004 Polaris WideTrak | Owners Manual - Page 55
is in use. If the park brake light does not come on when the park brake or service brake is in use, have it serviced by your dealer. WARNING If the park brake lever lock is partially or entirely engaged while riding, overheating of the brakes could occur, resulting in - 2004 Polaris WideTrak | Owners Manual - Page 56
PRE-RIDE INSPECTIONS Before Starting the Engine Check for Proper Operation of Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may - 2004 Polaris WideTrak | Owners Manual - Page 57
Start the Engine and Check PRE-RIDE INSPECTIONS n Transmission: Make sure the reverse is not engaged before starting your machine. n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and start the engine. n Lighting Check - 2004 Polaris WideTrak | Owners Manual - Page 58
your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 51. Starting a Cold Engine (Manual Start) Do not depress the throttle until the engine starts. 1. Turn key to ON. 2. Pull kill switch (shut-off switch) up to RUN - 2004 Polaris WideTrak | Owners Manual - Page 59
Starting the Engine OPERATION Starting a Cold Engine (Electric Start) Do not depress the throttle until the engine starts. CHOKE TOGGLE POSITIONS 1. Flip choke toggle to FULL ON. or Off 2. Pull kill switch (shut-off switch) up to RUN. 3. Turn key to START or and crank engine. Half On 4. After the - 2004 Polaris WideTrak | Owners Manual - Page 60
OPERATION Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of gasoline with one pint of Polaris injection oil - 2004 Polaris WideTrak | Owners Manual - Page 61
Engine Break-In OPERATION Oil Injection System CAUTION Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tankful of fuel. If the oil level doesn't go down, contact your dealer immediately. Always fill the oil reservoir when refueling. - 2004 Polaris WideTrak | Owners Manual - Page 62
snowmobile. Track Warm-Up Follow these steps to ensure proper warm-up of the engine, drive train and track. 1. Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper. The track should be approximately 4″ (10 cm) off the ground. 2. Start the engine and allow it - 2004 Polaris WideTrak | Owners Manual - Page 63
Fuel OPERATION WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a S S S S S well ventilated area. Do not smoke or allow open flames or sparks in - 2004 Polaris WideTrak | Owners Manual - Page 64
OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used. Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There's a great deal of variability in the quality of the 87 octane - 2004 Polaris WideTrak | Owners Manual - Page 65
Fuel OPERATION Fuel Reserve Capacity (Mechanical Gauge) There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES. Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to - 2004 Polaris WideTrak | Owners Manual - Page 66
OPERATION Oil Low Oil Indicator Light The low oil indicator light will indicate when to add oil. See page 59 for oil recommendations. When the low oil indicator light is on, oil should be added before further operation of the snowmobile. Visually check the oil level in the bottle. The engine may be - 2004 Polaris WideTrak | Owners Manual - Page 67
condition and may cause serious engine damage. Jet the carburetors carefully for elevation and temperature according to the jetting charts in your Owner's Manual Supplement. NOTE: Always ensure that the correct jets are installed in the machine for your geographical area. Use care when jetting down - 2004 Polaris WideTrak | Owners Manual - Page 68
OPERATION Engine Stop Switch Push down on the engine stop switch (A) to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position. A Throttle Safety Switch B Test the throttle - 2004 Polaris WideTrak | Owners Manual - Page 69
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 - 2004 Polaris WideTrak | Owners Manual - Page 70
OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 66 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch Tether - 2004 Polaris WideTrak | Owners Manual - Page 71
Emergency Starting OPERATION Your machine is equipped with a tool kit containing essential tools for emergency use. Machine's equipped with electric start have a recoil for emergency starting. On non-electric start models, if the recoil starter system fails, an emergency start strap is provided in - 2004 Polaris WideTrak | Owners Manual - Page 72
OPERATION Reverse Operation WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. S S S S Always look behind the vehicle before and while backing. Always avoid sharp turns. Shift to or from reverse only when stopped. Always apply - 2004 Polaris WideTrak | Owners Manual - Page 73
Reverse Operation OPERATION Electronic Reverse (PERCt) Electronic reverse will activate only if the engine is below 4000 RPM (3000 RPM on fan cooled models). If your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described below (Altitude Settings). Always make - 2004 Polaris WideTrak | Owners Manual - Page 74
OPERATION 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 4″ (20 cm) off the ground. Remove the key and cover - 2004 Polaris WideTrak | Owners Manual - Page 75
Maintenance Program MAINTENANCE To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks outlined in this manual. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles - 2004 Polaris WideTrak | Owners Manual - Page 76
MAINTENANCE Maintenance Chart The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use - 2004 Polaris WideTrak | Owners Manual - Page 77
plug condition Inspect coolant filter, replace if necessary Grease ski pivots Grease ski spindles Grease center steering arm(s) Lubricate steering post support bracket and pivot (aerosol) Check cylinder base stud torque on all Polaris engines. (Specification: 32 ft. lbs ± 2 ft. lbs.) (Dealer) Grease - 2004 Polaris WideTrak | Owners Manual - Page 78
MAINTENANCE Maintenance Log Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. 150 Mile (240 km) Initial Maintenance Inspection Authorized - 2004 Polaris WideTrak | Owners Manual - Page 79
Maintenance Log MAINTENANCE Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service Mileage Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Type of Service Mileage 77 - 2004 Polaris WideTrak | Owners Manual - Page 80
ski pivots at the fittings as shown. S Grease the jackshaft and driveshaft clutch side bearings. S Use an aerosol lubricant on the steering post support bracket. S Grease the center steering arms. S Grease the steering post lower pivot. S Grease the rear suspension pivot shafts (raise the rear of - 2004 Polaris WideTrak | Owners Manual - Page 81
Lubrication MAINTENANCE The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the - 2004 Polaris WideTrak | Owners Manual - Page 82
MAINTENANCE Lubrication Jackshaft Bearing Greasing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps - 2004 Polaris WideTrak | Owners Manual - Page 83
Lubrication MAINTENANCE Throttle Cable Lubricate the throttle cable (1) lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown. Choke and Cable Lubricate the choke slide (2) and cables lightly with oil or grease. Before turning the engine - 2004 Polaris WideTrak | Owners Manual - Page 84
MAINTENANCE Lubrication Gearcase Oil Level (WideTrak) It's the operator's responsibility to maintain proper gearcase oil level. To check the oil level, place the machine on a level surface. The oil level should be between the "safe" marks on the dipstick (A). See your Polaris dealer for the - 2004 Polaris WideTrak | Owners Manual - Page 85
Lubrication MAINTENANCE Chaincase Oil Level It's the operator's responsibility to check and maintain the proper chaincase oil level. To check the oil level, place the machine on a level surface. The oil level should be between the "safe" marks on the dipstick (A). Add Polaris chaincase oil (PN - 2004 Polaris WideTrak | Owners Manual - Page 86
. This selection could cause the customer who normally operates the engine under medium or light duty to have spark plug failure. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your machine. CAUTION A spark plug with a heat range too high will always cause engine - 2004 Polaris WideTrak | Owners Manual - Page 87
the correct main jet is installed in the carburetor(s). Refer to the Owner's Manual Supplement or see your dealer. 1. Normal The normal insulator tip is gray, This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip - 2004 Polaris WideTrak | Owners Manual - Page 88
MAINTENANCE Intake Filter General Maintenance The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. CAUTION Operating the snowmobile with the intake filters removed - 2004 Polaris WideTrak | Owners Manual - Page 89
require inspection of the water pump belt at 1500 miles (2400 km). Inspect belt width (A) and condition. Replace if cracked or worn past the width service limit (.250″ / 6.35mm). New belt width is approximately .345″ (8.75 mm). See your Polaris dealer if the belt needs to be replaced. A 87 - 2004 Polaris WideTrak | Owners Manual - Page 90
MAINTENANCE General Maintenance Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor anything that may cause the fuel to ignite, such as open flames, sparks, heaters, trouble lights, cigarettes, etc. Review the gasoline warnings found on page 61. Plug Cleaning Procedure - 2004 Polaris WideTrak | Owners Manual - Page 91
in the bottom of the oil tank. After changing the oil filter, bleed the oil injection system of all trapped air. See your dealer for instructions, or have your dealer perform the filter change and bleeding operation for you. NOTE: The direction of the arrows indicates the direction of flow through - 2004 Polaris WideTrak | Owners Manual - Page 92
MAINTENANCE General Maintenance General Carburetor Information The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It's your dealer's responsibility to make sure the correct main jet is - 2004 Polaris WideTrak | Owners Manual - Page 93
cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets. WARNING Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure - 2004 Polaris WideTrak | Owners Manual - Page 94
MAINTENANCE Coolant Mixture General Maintenance The coolant supplied in the system is a 50/50 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing at temperatures to -34° F (-37° C). If greater protection is required, the percentage of antifreeze to - 2004 Polaris WideTrak | Owners Manual - Page 95
system should be completely drained every two years and a fresh 50/50 or 60/40 mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your - 2004 Polaris WideTrak | Owners Manual - Page 96
MAINTENANCE General Maintenance Bleeding the Cooling System CAUTION If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced. Surge Tank Models 1. Remove - 2004 Polaris WideTrak | Owners Manual - Page 97
General Maintenance Drive Chain Tension MAINTENANCE 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 adjuster bolt jam nut (A). 3. - 2004 Polaris WideTrak | Owners Manual - Page 98
MAINTENANCE General Maintenance Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Firmly depress the brake lever and A measure the clearance between the lever and handlebar grip. This distance, called brake lever reserve (A), should be no less than 1/2″ (1.3 cm). Brake pads - 2004 Polaris WideTrak | Owners Manual - Page 99
General Maintenance Brake Components MAINTENANCE 1 2 3 5 4 1. 2. 3. 4. 5. Brake Caliper Chaincase Brake Disc Backing Plate Brake Pad Material (Replace when thickness is less than 1/16″). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops - 2004 Polaris WideTrak | Owners Manual - Page 100
MAINTENANCE Brake Fluid General Maintenance 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 - 2004 Polaris WideTrak | Owners Manual - Page 101
General Maintenance MAINTENANCE 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 - 2004 Polaris WideTrak | Owners Manual - Page 102
Lever Travel WARNING Improper brake adjustment could result in brake failure and lead to serious injury or death. See your dealer for brake service. Frequently inspect the brake lever reserve (A), which is the clearance between the lever and the brake block. To inspect, firmly depress the brake - 2004 Polaris WideTrak | Owners Manual - Page 103
General Maintenance Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure: 1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6m) from a wall. 2. Measure the distance from the floor to the center of the headlight and - 2004 Polaris WideTrak | Owners Manual - Page 104
MAINTENANCE General Maintenance Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases 2 from the spring retainer. NOTE: Do not touch a halogen bulb with bare fingers. Oil from 3 skin leaves a residue, causing a hot spot that will shorten the - 2004 Polaris WideTrak | Owners Manual - Page 105
General Maintenance Taillight Replacement MAINTENANCE 1. Remove the rear storage cover (A) if equipped. 2. Depending on your model, remove the screws (B) securing either the taillight housing (C) or the lens cover (D). 3. Remove and replace the bulb (E). 4. Reassemble all components. A E D B B E C - 2004 Polaris WideTrak | Owners Manual - Page 106
are crucial to maintaining optimum performance. See your Owner's Manual Supplement for the recommended offset between the drive and driven change the shift pattern, resulting in poor performance. See your dealer for service and adjustments. NOTE: A worn belt will continue to function, but will - 2004 Polaris WideTrak | Owners Manual - Page 107
General Maintenance MAINTENANCE Periodically check the condition and tension of the drive belt, and always carry a spare belt. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. The following - 2004 Polaris WideTrak | Owners Manual - Page 108
MAINTENANCE General Maintenance Drive Belt Installation 1. Drop the drive belt over the A drive clutch and pull back the slack (A). NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read - 2004 Polaris WideTrak | Owners Manual - Page 109
the distance between the sheaves and out (counterclockwise) to decrease the distance. 3. Tighten the jam nut. Clutch Center Distance See your Owner's Manual Supplement for recommended center distance for your machine. If adjustment is necessary, see your dealer. Due to tolerances in belt length, it - 2004 Polaris WideTrak | Owners Manual - Page 110
MAINTENANCE Torque Stop General Maintenance If your snowmobile is equipped with an engine torque stop (1), periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be a minimum of .010″ to a maximum of .030″ from the engine case (2). Adjust if - 2004 Polaris WideTrak | Owners Manual - Page 111
and routine maintenance. Your tool kit 2 will contain only the tools applicable to your model. 3 1. Emergency Start Strap 4 (manual start models) 5 2. Phillips Screwdriver 3. Tubular Socket 4. Tubular Socket Handle 7 5. Wrench 6 6. Flat Screwdriver 7. Shielded Screwdriver (only 8 models with Indy - 2004 Polaris WideTrak | Owners Manual - Page 112
MAINTENANCE Fall Tune-Up General Maintenance For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Maintenance Items The tools and maintenance items mentioned in this - 2004 Polaris WideTrak | Owners Manual - Page 113
adjustments should be made only after the track is warmed up and limber. 1. Turn the machine off. 2. Lift the rear of the C D machine and safely support it off the ground. Hi-fax Track 3. Place the recommended weight or downward pressure on the track at the specified distance ahead of the center - 2004 Polaris WideTrak | Owners Manual - Page 114
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 - 2004 Polaris WideTrak | Owners Manual - Page 115
rotate a damaged track under power. Using a hoist, safely lift and support the rear of the snowmobile off the ground. Rotate the track by Lubrication WARNING Operating with insufficient lubrication between the Hi-fax and track guide clips can cause track failure, loss of vehicle control and loss - 2004 Polaris WideTrak | Owners Manual - Page 116
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 - 2004 Polaris WideTrak | Owners Manual - Page 117
Steering System X 10″ MAINTENANCE 10″ Y Edge IFS X 10″ 10″ Y WideTrak 115 - 2004 Polaris WideTrak | Owners Manual - Page 118
MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check fasteners and tighten if necessary. Specific fasteners that should be checked are marked with a + in the following illustrations. All Steering Except CRC + + + + + + + Edge IFS Steering - 2004 Polaris WideTrak | Owners Manual - Page 119
weekly to maintain positive steering characteristics. Carbide skags must be replaced if any abnormal wear or chipping is found. Skag Replacement 1. Raise and support the front of the machine so the skis are approximately 6″ (15.2 cm) from the ground. 2. Remove the attaching hardware and pry the - 2004 Polaris WideTrak | Owners Manual - Page 120
MAINTENANCE Hi-Fax Wear Suspension Maintenance Check Hi-fax wear by measuring the thickness at several points along the rail (A). Replace Hi-fax when a thickness of 7/16″ is reached (3/8″ on WideTrak models). See your dealer for Hi-fax replacement. If excessive Hi-fax wear occurs due to poor snow - 2004 Polaris WideTrak | Owners Manual - Page 121
reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip: n Check rear idler wheel bolts for tightness. n Check rear - 2004 Polaris WideTrak | Owners Manual - Page 122
the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer. Engine and Carburetor Protection Proper preparation of . See page 126 for the part numbers of Polaris products. Follow the instructions on the can, running the engine for five minutes to get additives through - 2004 Polaris WideTrak | Owners Manual - Page 123
: 1. Transfer unused fuel from the fuel tank to an approved fuel container using a siphon pump. Do not re-use fuel after storage. 2. Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward. 3. Remove the spark plug(s). 4. Rotate - 2004 Polaris WideTrak | Owners Manual - Page 124
MAINTENANCE Extended Storage Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely. See illustration. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Turn the - 2004 Polaris WideTrak | Owners Manual - Page 125
Battery MAINTENANCE WARNING Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immediate medical attention. KEEP OUT OF REACH OF CHILDREN. EXTERNAL: Flush with water. INTERNAL: Drink large quantities - 2004 Polaris WideTrak | Owners Manual - Page 126
MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When cleaning is necessary, remove the corrosion with a stiff wire brush. Wash terminals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and - 2004 Polaris WideTrak | Owners Manual - Page 127
Battery MAINTENANCE When your snowmobile is placed in storage for one month or more: S Remove the battery. S Charge it to the proper level. S Store it in a cool dry place. S Check and/or charge monthly. Before using the battery, take it to your dealer for testing and recharging. Batteries may - 2004 Polaris WideTrak | Owners Manual - Page 128
POLARIS PRODUCTS Part No. 2870791 2871098 2871097 2871721 2871722 2874438 2874439 2873105 2872951 2871312 2871322 2871423 2871329 2871323 2871534 2871326 2870652 2870990 2872893 2870505 2872889 2872890 Description Engine Lubricants Fogging Oil (12 oz. Aerosol) Premium 2-Cycle Engine Oil (qt.) - 2004 Polaris WideTrak | Owners Manual - Page 129
Engine Troubleshooting TROUBLESHOOTING CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Erratic engine operating RPM during acceleration or load variations Probable Cause Drive clutch binding Solution Disassemble - 2004 Polaris WideTrak | Owners Manual - Page 130
TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive system Probable Cause Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain - 2004 Polaris WideTrak | Owners Manual - Page 131
Engine Troubleshooting Problem Engine turns but fails to start TROUBLESHOOTING Solution Probable Cause Faulty cause seizure resulting in loss of power). SEE YOUR DEALER. This indicates a major engine problem that must be repaired before engine is run. Change plug(s). Check fuel filter flow. - 2004 Polaris WideTrak | Owners Manual - Page 132
Edge 136 Suspension Problem Rear suspension bottoms too easily Suspension Troubleshooting Solution (perform only one change at a time) - Increase torsion spring preload. - Increase rear track compression damping by turning screw on rear track shock clockwise (factory - 2004 Polaris WideTrak | Owners Manual - Page 133
Suspension Troubleshooting Problem Rear suspension bottoms too easily TROUBLESHOOTING Edge Touring Suspension (ETS) and ETS ACE Solution (perform only one change at a time) - Adjust RCA forward (see setup decal under hood). - Adjust coil over - 2004 Polaris WideTrak | Owners Manual - Page 134
TROUBLESHOOTING Belt Troubleshooting Causes Driving at low RPM Insufficient warm-up Belt Wear/Burn Diagnosis Solutions Drive at higher RPMs. Gear the machine down. Check belt deflection. Warm - 2004 Polaris WideTrak | Owners Manual - Page 135
information contained in this manual. Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you. When contacting us about parts, service, or warranty, always provide the following information: 1. Serial number 5. Details of trouble experienced 2. Model number - 2004 Polaris WideTrak | Owners Manual - Page 136
and set-up of your snowmobile is very important in ensuring trouble-free operation. Purchasing a snowmobile in the crate or without proper 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 - 2004 Polaris WideTrak | Owners Manual - Page 137
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 - 2004 Polaris WideTrak | Owners Manual - Page 138
dealer to perform the required vehicle PreDelivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to products for lubrication and maintenance as directed by the Owner's manual is highly recommended. Should a failure occur during the warranty - 2004 Polaris WideTrak | Owners Manual - Page 139
oil. S Piston seizures, unless caused by a defective engine component. S Failures caused due to improper adjustments. S Failure due to unauthorized service. S 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 - 2004 Polaris WideTrak | Owners Manual - Page 140
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 - 2004 Polaris WideTrak | Owners Manual - Page 141
Reverse ...71 Emergency Starting ...69 Emergency Stopping ...68 Engine and Carburetor Protection 120-121 Engine Break-In ...58 Engine Stop Switch ...55, 66 Engine Troubleshooting ...127-129 ETS ACE ...43-44 ETS ACE Settings ...43-44 ETS Adjustments ...41-42 Excessive Speed ...13 Exhaust System ...91 - 2004 Polaris WideTrak | Owners Manual - Page 142
Chart ...74-75 Maintenance Log ...76-77 Maneuverability ...18 Manual Start ...56 Mechanical Reverse ...70 Mirror Adjustment ...55 Moving Parts 27 Scissor Stop, Edge 136 ...38-40 Second Year Engine Service Contract 137 Service And Warranty Information . . 133 Shock Absorber Components ...31 Shock - 2004 Polaris WideTrak | Owners Manual - Page 143
Traction Products ...48 Transmission ...55 Transporting the Snowmobile ...122 TROUBLESHOOTING ...127-132 V Variable Exhaust System ...59, 87 Vehicle WARRANTY ...133-138 Water Pump Belt Inspection ...87 Water/Sediment Trap Service ...88 Wear Strips ...50 Weight Transfer During Acceleration, Edge 136 - 2004 Polaris WideTrak | Owners Manual - Page 144
For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone (763) 417-8650 Fax (763) 542-0599 Part No. 9918226 Rev 02 Printed in USA
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2004
Touring & WideTrak
Snowmobiles
2004
Touring & WideTrak
Snowmobiles
Owner's Manual
for Vehicle Maintenance
and Safety
Owner's Manual
for Vehicle Maintenance
and Safety