Polaris 800 Pro X, Owner'S Manual

Page 1: ...2004 PRO X Snowmobiles 2004 PRO X Snowmobiles Owner s Manual for Vehicle Maintenance and Safety Owner s Manual for Vehicle Maintenance and Safety...

Page 2: ...haust 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 k...

Page 3: ...A Polaris owner s Web site designed just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it ou...

Page 4: ...uction 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 ref...

Page 5: ...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 abou...

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Page 7: ...snowmobile s controls and features The Perfect Fit 32 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 48 This section explai...

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Page 9: ...ur 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 dealer at specific mileage...

Page 10: ...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...

Page 11: ...numbers are essential to its recovery and identification 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...

Page 12: ...on your vehicle or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert caut...

Page 13: ...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 Failu...

Page 14: ...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 c...

Page 15: ...reference To better enjoy your ride be prepared be warm and be comfortable Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills Operators with cog...

Page 16: ...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 Ice and Snow Build up Before driving manually turn the sk...

Page 17: ...ur 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 con...

Page 18: ...er side of the hill If you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling bac...

Page 19: ...remote don t defeat the purpose 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...

Page 20: ...track and or engine If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the throttle is opened the snowmobile will b...

Page 21: ...removed Clutches Do not attempt to service the clutches All clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynamically bal...

Page 22: ...Your Polaris snowmobile is a well engineered and well constructed recreational vehicle Follow the recommended maintenance program outlined beginning on page 69 of this manual to ensure that all critic...

Page 23: ...if they ve taken a snow mobile safety course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safe ty course Everyone can benefit from the cour...

Page 24: ...26 10 6 21 37 53 69 85 100 116 132 148 Wind Speeds Great er Than 40 MPH Have Little Added Little Danger For Properly Clothed Person Increasing Danger Great Danger Have Little Added Effect Clothed Per...

Page 25: ...egible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Clutch Cover Warning Th...

Page 26: ...and Locations Track Warning The track warning decal is located on the rear of the tunnel Passenger Warning Polaris PRO X snowmobiles are designed for one operator only A No Passenger warning decal is...

Page 27: ...25 SAFETY Safety Decals and Locations Reverse Warning Some Polaris snowmobiles are equipped with reverse These models will have a reverse warning decal on the lower dash WARNING AVERTISSEMENT...

Page 28: ...26 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...

Page 29: ...27 SAFETY Safety Decals and Locations Operation Warning AVERTISSEMENT...

Page 30: ...t of specific features on your machine Accessories are available from your Polaris dealer 1 Brake Lever 2 Speedometer 3 Reverse Indicator Light 4 Tachometer 5 Temperature Light 6 Engine Stop Switch 7...

Page 31: ...29 FEATURES AND CONTROLS 10 6 7 8 9 1 2 4 3 5 16 14 12 11 13 15 1...

Page 32: ...Hood 2 Headlight 3 Windshield 4 Handlebar 5 Seat 6 Storage Compartment Trunk 7 Taillights 8 Rear Bumper 9 Snow Flap 10 Track 11 Suspension 12 Trailing Arm 13 Nosepan 14 Front Bumper 15 Skis 9 4 3 2 1...

Page 33: ...ese conditions exists and the sensor remains activated see your Polaris dealer Possible Cause Solution Poor quality fuel Replace with higher quality fuel Improper jetting Verify and adjust per jetting...

Page 34: ...after each adjustment until the best ride is achieved Independent Front Suspension IFS The IFS is made up of the skis 1 front shocks and springs 2 and the components that connect these parts to both...

Page 35: ...r down as far as it will go on the shock rod and test ride the machine The bumper will move up on the rod in direct relation to the amount of travel If the shock travel is full the bumper will be seat...

Page 36: ...ame adjustment To increase front shock spring preload grasp the spring and turn it to the right Turn it to the left to decrease preload In the illustrations at right B indicates high preload and C ind...

Page 37: ...d if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness See your Polaris dealer for more information Changing shock valving on RydeFX or Walker Eva...

Page 38: ...change For further assistance see your dealer Suspension Performance Tips S Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding s...

Page 39: ...nce between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y from X Sag X Y Adj...

Page 40: ...ride is desired Contact your dealer for more information The following information is provided only as a guideline to be used for initial suspension set up Your set up may vary based on your desired...

Page 41: ...s Adjustments to the compression damping are made by turning the clicker knob A on the shock reservoir Position 1 is the softest or least compression damping As the knob is turned to higher numbers co...

Page 42: ...coupling links the movement of the front and rear torque arms to each other There are two types of rear suspension coupling Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the m...

Page 43: ...g the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performance An adjustment dot is located on...

Page 44: ...increase weight transfer or ski lift during acceleration move the RRSS to the rearward upper position The RRSS may also be rotated to a lower position for even more weight transfer if desired A Low P...

Page 45: ...bolts on the top of the riser depending on the type of adjustment required 3 Adjust the handlebar to the desired angle Be sure the handlebar brake lever and throttle lever operate smoothly and do not...

Page 46: ...870668 Use only Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in S Non compliance with government industry requirements S Voiding of warra...

Page 47: ...ed by contact with roads and other bare terrain The addition of carbide skags is recommended with studded tracks to help maintain proper vehicle steering and control Similarly if your machine is equip...

Page 48: ...8 2 86 cm from outside edge of the track CAUTION If traction products are added to the track wear strips must be installed in the tunnel to avoid excessive wear Never add shims to the wear strip Track...

Page 49: ...tudding is used Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction accessories Components as viewed from the rear of the track 1 Top of tunne...

Page 50: ...s evenly and smoothly The lever should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly DO NOT start the engine Have the throttle servic...

Page 51: ...the brake lever Proper operation depends on an adequate supply of air and moisture free hydraulic brake fluid in the system If the brake lever feels spongy when squeezed check the level and condition...

Page 52: ...not force the lock or it may break To release the lock squeeze the brake handle until the lever returns to the unlock position The park brake light on the console will light up when the park brake le...

Page 53: ...track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure caused...

Page 54: ...h and low beam taillight and brake light for normal operation n Mirror Adjustment If equipped adjust your mirrors so they can be used to their full advantage n Check Surroundings to Verify Clear Opera...

Page 55: ...ck resulting in premature wear and failure Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating on ice hard p...

Page 56: ...s injection oil for each five gallons of fuel This in addition to the lubrication supplied by the injection system will assure proper engine break in CAUTION Excessive heat build up during the first t...

Page 57: ...highest performance products available for your snowmobile s engine Refer to the table below to determine the recommended oils for use in your Polaris snowmobile Never mix brands of oil Serious chemi...

Page 58: ...m from side to side This will loosen frozen snow from the ski bottoms allowing the machine to move forward more easily 6 The engine drive system and track are now properly warmed up and the machine ma...

Page 59: ...the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed...

Page 60: ...the key switch to the ON PREM position When the engine is started a yellow Premium Fuel light illuminates on the instrument panel When the key is in this position the fuel must be a minimum of 91 octa...

Page 61: ...methanol See page 112 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deicers or water absorbing additives are not required and should not be...

Page 62: ...le and the result could be sludge formation filter blockage and reduced cold weather flow rates All Polaris oils are compatible with each other Always maintain the oil level above the tank s low level...

Page 63: ...altitude of 0 2000 ft 0 600 meters and ambient temperatures between 10 to 10 F 23 to 12 C All carburetors must be re calibrated if operated outside this production temperature and or altitude range Th...

Page 64: ...on shown in the illustration B Apply a slight amount of throttle A properly functioning switch must shut down the engine The throttle safety switch is designed to stop the engine whenever all pressure...

Page 65: ...the throttle cable 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...

Page 66: ...ngine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Throttle Safety Switch Interrupts ignition circuit All Tether Switch Option Interrupts ignition circuit All Excessive or...

Page 67: ...nd rotate clockwise slightly to relieve belt tension 3 Starting at one of the tower struts wind the strap counterclockwise around the clutch as shown 4 Pull the strap abruptly so the strap comes free...

Page 68: ...strument panel will indicate that the machine is in reverse 3 Slowly apply the throttle until movement starts and you re sure the machine is in reverse NOTE The maximum engine RPM will be 6000 when in...

Page 69: ...ure the machine is in forward gear Altitude Setting At higher altitudes above 6000 feet the engine will require a different ignition setting to improve the success of the reverse system To set for a h...

Page 70: ...the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed obje...

Page 71: ...iles 240 km 500 miles 800 km and 1000 miles 1600 km These inspections should be performed by a qualified service technician For continued optimum performance and component life continue maintenance ch...

Page 72: ...ottle lever operation Daily 48 62 Check operation of headlights taillight brakelight Daily 52 Check park brake function Daily 50 Secure hood Daily 51 Check track alignment X 102 Steering arm and tie r...

Page 73: ...X Grease lower steering post pivot X X X 74 Grease driveshaft bearing always perform before storage X X 76 Check and drain water trap X X 82 Grease rear suspension pivot shafts X X 75 Grease jackshaft...

Page 74: ...ile 240 km Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 500 Mile 800 km Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Tec...

Page 75: ...Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Type of Service Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technici...

Page 76: ...ft and right spindles Raise the front end of the ma chine to permit better grease entry into the spindle area S Lubricate both of the front ski pivots at the fittings as shown S Grease the jackshaft a...

Page 77: ...and before off season storage each year Lack of lubrication will adversely affect your ride and the life of the suspension For detailed information about suspension lubrication and adjustments see you...

Page 78: ...24 4 Nm Driveshaft Bearing Greasing Inject grease into the fitting on the speedometer drive adaptor until grease purges from inside or outside the bearing seal approximately two pumps Throttle Cable...

Page 79: ...A Add Polaris synthetic chaincase oil through the dipstick opening Do not overfill See page 112 for the part numbers of Polaris products Flush the chaincase after the first 500 miles then every 1000 m...

Page 80: ...fer to your Owner s Manual Supplement for the specific spark plug to be used in your machine A new engine can cause temporary spark plug fouling due to the preservative added during the assembly proce...

Page 81: ...or the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The...

Page 82: ...to remove any accumulation of snow NOTE These illustrations are general representations Your model may differ 1 Intake Foam Filter 2 Air Intake box 1 1 2 Operating the snowmobile with the intake filt...

Page 83: ...l recommendation chart on page 55 The use of other lubricants may cause improper function of the valve mech anism and increase the frequency of required cleaning due to excessive build up of carbon de...

Page 84: ...tion a container or shop towels to catch the contaminated gasoline 3 Slide the clamp 1 away from the drain plug 2 and remove the drain plug from the sediment tube 4 Wipe residue from the plug and rein...

Page 85: ...have an oil filter that s built into the oil sending unit located in the bottom of the oil tank Any time the sending unit is replaced bleed the oil injection system of all trapped air See your dealer...

Page 86: ...important Properly adjusted carburetors can greatly improve engine performance fuel economy engine life and reliability If you notice any of the following conditions the carburetor may need adjustment...

Page 87: ...weak or missing retaining springs or damper support grommets Engine Cooling Liquid Cooled Models The cooling system on liquid cooled models consists of the following major components S Coolant bottle...

Page 88: ...Temperature Indicator Light The high temperature indicator light is controlled by a switch in the engine cooling system on liquid cooled models If the engine coolant reaches a certain temperature the...

Page 89: ...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 snowmobile If the pressure cap A needs replacement contac...

Page 90: ...ge the air from the crossover hose or rear cooler so you can observe this air reaching the bottle 4 Tilt the machine slightly onto its left side so that the coolant bottle is the highest point in the...

Page 91: ...nsioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut A 3 Finger tighten the adjuster bolt B until it can no longer be adjusted by...

Page 92: ...when the brake pad material becomes thinner than the backing plate approximately 1 16 A kit is available for replacing brake pads See your dealer A Brake failure during operation can result in seriou...

Page 93: ...Brake Pad Material Replace when thickness is less than 1 16 Excessive Brake Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops as described on page 90 the m...

Page 94: ...luid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of ac...

Page 95: ...id into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the brake lever 6 Repeat steps 4...

Page 96: ...nter of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be aimed...

Page 97: ...Lift spring carefully around wire harness 2 and flip to outside of housing 3 With the wire harness attached to the bulb 3 withdraw bulb from housing 4 Grasp bulb by metal base and carefully separate...

Page 98: ...M belts be used Other belts may match the dimensions but can drastically change the shift pattern resulting in poor performance See your dealer for service and adjustments NOTE A worn belt will contin...

Page 99: ...and open the clutch guard 3 Locate the L wrench in the tool kit and install it into the open threaded hole in the outer sheave of the clutch Rotate the wrench until the sheaves open far enough to rem...

Page 100: ...he 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 adjustm...

Page 101: ...ntain only the tools applicable to your model 1 Emergency Start Strap 2 Phillips Screwdriver 3 Tubular Socket 4 Tubular Socket Handle 5 Wrench 6 Screwdriver 550 PRO X 7 Scissor Stop Wrench 8 Box End W...

Page 102: ...ve Belt SExtra Set of Spark Plugs STow Rope SExtra Oil SFuel Deicer SWinter Survival Kit STrail Map SOwner s Manual SFirst Aid Kit Fall Tune Up For maximum performance arrange for a fall service tune...

Page 103: ...e weight is hanging 4 Check for specified slack between the wear surface of the track clip and the plastic Hi fax C If the track needs adjustment 5 Loosen rear idler shaft bolt D 6 Loosen locknuts A 7...

Page 104: ...l 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...

Page 105: ...sive wear NOTE If excessive Hi fax wear occurs due to poor snow conditions additional wheel kits are available See your dealer for more information NOTE Track damage or failure caused by operation on...

Page 106: ...104 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all fasteners and tighten if necessary Specifically check fasteners marked with a...

Page 107: ...e measurement between the skis at point X should be 1 8 to 1 4 greater than at point Y NOTE If the skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may a...

Page 108: ...rom the ground 2 Remove the attaching hardware and pry the skag A downward 3 Remove the forward portion of the skag Reverse this procedure for new skag installation Worn skis and or skags will adverse...

Page 109: ...ntenance Hi Fax Wear Check Hi fax wear by measuring the thickness at several points along the rail A Replace Hi fax when a thickness of 7 16 1 1 cm is reached Take the machine to your dealer for Hi fa...

Page 110: ...er skag condition Extended Storage Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components Cleanin...

Page 111: ...he engine must be fogged with fogging oil Follow the engine fogging instructions provided on the can See page 112 Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank See...

Page 112: ...ton until it s at bottom dead center BDC the lowest position in the cylinder On twin cylinder models the opposite piston will be up 5 Pour approximately two ounces of Polaris injector oil into the spa...

Page 113: ...on Transporting the Snowmobile Whenever the snowmobile is transported 1 Turn the fuel valve clockwise to OFF to shut off the fuel supply 1 Turn the valve counter clockwise to ON to turn the fuel suppl...

Page 114: ...icants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogelt Coolant 28713...

Page 115: ...clearance and replace if necessary SEE YOUR DEALER Harsh drive clutch engagement Drive belt worn or too narrow Excessive belt sheave clearance Replace drive belt SEE YOUR DEALER Drive belt turns over...

Page 116: ...elt sheave clearance Loose torque stop Sticky clutch Inspect and replace if necessary SEE YOUR DEALER Inspect and adjust SEE YOUR DEALER Engine doesn t turn Seized engine Hydrostatic lock SEE YOUR DEA...

Page 117: ...may be necessary to change plug s however the plug s may operate satisfac torily when dried Running too lean a mixture too small a main jet will cause seizure resulting in loss of power SEE YOUR DEAL...

Page 118: ...ack tension Machine darts from side to side Make sure skis are aligned properly Make sure spindles and all steering components are free turning Make sure skags are straight on skis Check Hi fax and re...

Page 119: ...educe RPM Avoid riding in high ambient temperatures Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather a...

Page 120: ...3 Dealer name 7 Previous correspondence 4 Date of purchase Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris C...

Page 121: ...not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has...

Page 122: ...y service you must present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility Polaris recommends that you use your origi...

Page 123: ...ls Brake components Throttle body components Seat components Engine components Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumabl...

Page 124: ...omatic with no additional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate...

Page 125: ...take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verifi...

Page 126: ...Drive Belt Deflection 98 Drive Belt Installation 97 Drive Belt Removal 97 Drive Chain Tension 89 D Driver Awareness 15 Driveshaft Bearing Greasing 76 Driving Downhill 17 Driving in Hilly Terrain 16 D...

Page 127: ...13 S SAFETY 10 27 Safety Decals and Locations 23 27 Sag 37 Scissor Stop 40 41 Service Contract 122 Shock Absorber Components 33 Shock Spring Preload Front 34 Shock Valving 35 Shock Clicker 39 Signal w...

Page 128: ...Transporting the Snowmobile 111 TROUBLESHOOTING 113 117 V Variable Exhaust System 55 81 Vehicle Identification Numbers 9 W Warning Labels 23 27 WARRANTY 118 123 Water Pump Belt Inspection 81 Water Sed...

Page 129: ...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 9918227 Printed in USA...