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Polaris 2002 manual Engine Break-In

Models: 2002

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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 for each five gallons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

CAUTION

Never mix brands of two cycle oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage and the voiding of engine warranty. The only oil recommended for this system is Polaris injection oil. This oil has been specially formulated for all temperatures and has extreme cold flow characteristics.

Do not operate at prolonged full throttle for the first three hours of operation. Vary the throttle openings and machine speeds to reduce friction on all close fitting machined parts and allow them to break in slowly without damage.

Adequate snow coverage is necessary to properly break in your machine. Avoid operating on ice, hard-packed surfaces, or roads. Snow will provide the lubrication and cooling your snowmobile needs for proper break-in. Inadequate cooling and lubrication will lead to overheating of the slide rail and track, 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.

Drive with extra caution during the break-in period. Perform regular checks on fluid levels, lines, and all other important areas of the machine.

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Polaris 2002 manual Engine Break-In

Contents

Page Proposition What’s the hottest thing on snow? Page Welcome Table of Contents HOW to USE this Manual Important Notes For Owners And Drivers Preservation Of The Environment Noise LevelAir Pollution HOW to USE this Manual Vehicle Identification Numbers Page Safety Operator Safety Safety Stay Away From Moving Parts Be Seated and in Position to Control the Vehicle Be Prepared for the UnexpectedDo Not Overload Cargo Carrier Always Wear Clothing Designed for SnowmobilingDisabled Operators Know the Limitations of the Machine Your Skills as a DriverSafety Ice and Snow Build-up Operation on Hard-Packed Snow or Slippery SurfacesDriving in Hilly Terrain Riding Downhill Do Not Operate Engine With Clutch Guard RemovedDo Not Operate Engine With Drive Belt Removed Do Not Service Clutches Yourself Cold Weather Drive-AwayMachine Maneuverability Powder Snow Operation Safety Responsible Driving Windchill/Temperature Charts Wind Chill Chart FWind Chill Chart C Airbox Warning Decal Safety Decals And LocationsClutch Cover Warning Decal Pressure Cap Warning DecalTrack Warning Decal Cargo Carrier Warning DecalPassenger Warning Standard Reverse Warning Decal Vehicle Capable of Excessive Reverse SpeedElectronic Reverse Warning Decal Operation Warning DecalOperation Warning Decal Text Before Starting Engine Features and Controls Location of Controls Features and Controls Features and Controls Features Features and Controls Features and Controls Page Perfect FIT Front Suspension Adjustments IFS Adjustment OptionsIndependent Front Suspension IFS Shock Absorber Components Adjusting Front ShockSpring Preload Changing Shock Valving Indy Select IFS Shock Rear Suspensions Suspension Performance TipsPerfect FIT Rear Spring Tension Perfect FIT Rear Torsion Spring Adjustment Xtra-12 Rear Torque Arm Adjustment SKS ModelsAdjustment Indy Select Front Track ShockIndy Select Rear Shock Suspension Coupling Optional Coil SpringsPosition Sensitive Shock PPS Front To Rear Coupling and the Front Rear Scissor Stop FrssRear To Front Coupling and the Rear Rear Scissor Stop Rrss Rear Rear Scissor Stop Rrss AttributesWeight Transfer During Acceleration Xtra-10 and Edge Rear Rear Scissor Stop RrssXtra-12 Rear Rear Scissor Stop Rrss Handlebar Adjustment Accessories Traction Products Perfect FIT Wear Strips Page Check Before Starting Engine Start the Engine and CheckThrottle Safety Switch Check Throttle and Brake for Proper OperationHydraulic Brakes Brake Lever TravelLever Feel Mechanical Brakes Park Brake Lever Lock Check for Proper Operation of Steering System Track InspectionCheck for Securely Latched Hood Check Surroundings to Verify Clear Operating Area Page Operation Starting Your Engine Starting a Cold Engine Manual StartStarting a Cold Engine Electric Start Starting a Warm EngineEngine Break-In Oil Injection System Variable Exhaust SystemLubrication Track Warm-Up Operation Fuel Premium Fuel Switch Fuel Reserve Capacity Fuel System DeicersLow Oil Indicator Light Low Oil Level Carburetion Engine Stop Switch Throttle Lever Stopping System What IT does Throttle ConditionStarting Reverse Operation Mechanical Reverse Operation Electronic Altitude Setting ForwardTowing Page Maintenance Polaris Recommended Maintenance Program Maintenance Chart Tighten idler adjusting bolt jam Mile 240 km Initial Maintenance Inspection Mile 1600 km Maintenance InspectionMile 3200 km Maintenance Inspection Additional Services Performed + + 102 LL L 104 105 Suspension Lubrication X-10, Edge Jackshaft Bearing Greasing Driveshaft Bearing GreasingCoupler Greasing WideTrak Throttle Cable Lubrication Choke and Cable LubricationChaincase Oil Level Gearcase Oil Level WideTrak Models Intake Filter Under Hood Air Intake System Spark Plug SelectionNormal OverheatingWet Fouled Spark Plug Removal and Replacement Variable Exhaust System V.E.S Water Pump Belt InspectionWater/Sediment Trap Service Plug Cleaning ProcedureFuel Filter/Fuel Lines Oil FilterCarburetor Adjustments General Carburetor InformationExhaust System Engine Cooling Liquid Cooled ModelsCoolant High Temperature Indicator Light Coolant MixtureCoolant Level Recovery System Models Flushing the Cooling SystemBleeding the Cooling System Surge Tank Models Drive Chain Tension Edge RMKsHydraulic Brake Inspection Brake Components Excessive Lever TravelReplenishing Brake Fluid Bleeding the Hydraulic Brake System Mechanical Brake Lever Travel Headlight Adjustment Installing the Bulb Removing Halogen Bulbs High/Low BeamRemoving Halogen Bulbs High Beam Installing the Side Bulbs Wrap Around Taillight Bulb ReplacementRemoving the Side Bulbs Standard Belt Removal Electronic Reverse Belt RemovalStandard Belt Installation Electronic Reverse Belt InstallationClutch System Clutch Alignment and Offset Drive Belt DeflectionReverse Kit Maintenance Clutch Center DistanceTorque Stop Oil Level Accessory Reverse KitChain Tension Oil ChangeTool Kit Tool Pouch ClipAlways keep the tool kit with the snowmobile Maintenance Items For Your ProtectionFall Tune-Up Suspension Weight Measurement Track Tension DataIf the track needs adjustment Track TensionTrack Alignment Track Lubrication Steering Inspection and Adjustment Ski Alignment 146 Skag Replacement Ski SkagsSkag Identification Hi-Fax Wear Cleaning and Preservation of Hood, Chassis, and Trim Controls and LinkageBearings Clutch and Drive SystemEngine and Carburetor Protection Battery Electrical ConnectionsTrack and Suspension Transporting the SnowmobileBattery Fluid Battery Connections Battery RemovalBattery Installation 156 Troubleshooting Suspension Troubleshooting Problem Solution perform only one change at a time12, 133″ Edge Edge RMK Xtra Lite Causes Solutions Belt Wear/Burn164 165 166 167 168 Warranty Obtaining Service and Warranty Assistance Service And Warranty InformationAdministration Polaris Anti-Theft SystemLimited Warranty 172 Engine Oil Conditions CoverageCoverage Exclusions Index 177 178