Snowmobile Polaris ProStar S4, Indy XC 129 / 137, Indy Adventure 137, Voyageur 146, Nordic Pro 146. Owner’s Manual (2024)

6. Repeat steps 4–5 until fluid flows from the bleeder valve in a solid stream

free of air bubbles.

WARNING

Overfilling the master cylinder leaves no room for fluid expansion and may

cause the brakes to lock, resulting in serious injury or death. Always add brake

fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level. See page

165.

8. Reinstall the gasket and cover.

LIGHTS

The headlight and taillight assemblies feature LED elements and are not
serviceable. If an LED fails to illuminate in either the headlight or taillight, the
entire assembly must be replaced.

FUSE REPLACEMENT

If the engine stops or will not start, or if an electrical component fails to operate,
a fuse may need replacement. Locate and correct any damage or short circuits
that may have caused the blown fuse, then replace the fuse.

NOTICE

Always replace a blown fuse with a new fuse having the same amperage rating

of the blown fuse. Never replace a fuse with a fuse of a higher amperage

rating.

167

MAINTENANCE

LOAD CENTER DETAILS

CIRCUIT

PIN

FUNCTION

Fan Relay

Coil Low

Relay In

Relay Out

Coil High

Fuel Pump Relay

Coil Low

Relay In

Relay Out

Coil High

Relay Start

Coil Low

Relay In

Relay Out

Coil High

EFI Relay

Coil Low

Relay In

Relay Out

Coil High

O2 HTR 5A Fuse

Power Out

169

MAINTENANCE

CIRCUIT

PIN

FUNCTION

Power In

Start 10A Fuse

Power Out

Power In

MAG Coil 5A Fuse

Power Out

Power In

PTO Coil 5A Fuse

Power Out

Power In

Fuel Pump 10A Fuse

Power Out

Power In

Fan CB 10A Fuse

Power Out

Power In

Chassis Relay

Coil Low

—

Not Applicable

Relay Out

Relay In

—

Not Applicable

Coil High

EFI 10A Fuse

Power Out

Power In

Lights 5A Fuse

Power Out

Power In

Key/Gauge 10A Fuse

Power Out

Power In

Rear Accessory 15A
Fuse

Power Out

Power In

High Beam 5A Fuse

Power Out

Power In

Front Accessory 15A
Fuse

Power Out

Power In

Spare Fuse

—

170

MAINTENANCE

CLUTCH SYSTEM

Periodically inspect clutch sheaves for damage, wear or belt residue. To
maintain optimum performance, clean with non-oil based cleaners such as
isopropyl alcohol.

WARNING

If you become aware of higher than normal clutch engagement or an unusual

vibration or shift pattern, see your authorized POLARIS dealer or qualified

person immediately. Do not operate the snowmobile until repairs have been

made.

All clutch maintenance and repairs can be performed by an authorized
POLARIS dealer. Any unauthorized modifications to clutches, such as adding or
removing weights, will void the warranty.

NOTICE

The bushings in the weights and rollers of POLARIS clutches are made of a

material that may be damaged if lubricated. Do not lubricate clutch bushings.

CLUTCH ALIGNMENT OFFSET

Clutch alignment offset is important for maintaining optimum performance. Your
dealer can perform service and adjustments. A special tool is required to check
for proper alignment.

DRIVE BELT CONDITION

Periodically check the condition and tension of the drive belt. Inspect the belt for
signs of excessive wear (frayed edges, missing cogs, cracks) and excessive
looseness. Replace the belt if any of these conditions exist. See page 226.

Always carry a spare drive belt. When placing the belt in the holder, orientate the
belt to match the profile of the hood.

For improved drive-away during extremely cold temperatures, remove the belt
and warm it to room temperature. Reinstall it before starting the snowmobile.

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MAINTENANCE

DRIVE BELT REMOVAL

NOTICE

Do not attempt to remove the drive belt after operating in reverse. The

snowmobile must be stopped after forward motion to prevent damage to

components during belt removal. Rotate the driven clutch counter-clockwise

1/4 turn by hand to ensure forward engagement before attempting to remove

the belt.

1. Stop the engine after operating in a forward motion.

2. Turn the ignition key off. Wait for the engine to come to a complete stop.

3. Lock the parking brake.

4. Remove the left side panel.

5. Rotate the driven clutch counter-clockwise 1/4 turn by hand to ensure

forward engagement.

6. Locate the L-wrench in the tool kit. Install the wrench into the open threaded

hole in the outer sheave of the clutch.

7. Turn the wrench clockwise until the sheaves open far enough to remove the

belt. If the wrench does not turn readily, rotate the driven clutch
counter-clockwise an additional 1/4 turn by hand and try again.

8. Remove the belt from the driven clutch.

DRIVE BELT INSTALLATION

1. With the L-wrench inserted into the threaded hole and the sheaves in the

open position, install the drive belt.

IMPORTANT

Install the belt so that the numbers can be read correctly on the left side of the

vehicle, or in the direction in which the belt was originally installed.

2. Rotate the belt clockwise to remove slack while removing the L-wrench.

3. Reinstall the side panel.

4. Break in the new belt. See page 141.

172

MAINTENANCE

DRIVE BELT DEFLECTION ADJUSTMENT

NOTICE

Proper drive belt deflection is an important factor for good transmission shifting

performance. Make sure the drive belt deflection is set to specification.

MEASUREMENT

Belt Deflection:

0.5″ (12.7 mm)

1. Loosen the 7/16 in. jam nut on the belt width adjuster screw.

2. Using a 1/8 in. Allen wrench, turn the set screw inward (clockwise) to

increase the distance between the sheaves (increase deflection) or outward
(counter-clockwise) to decrease the distance (decrease deflection).

SYMPTOM

CAUSE

Significant “clunk” noise when
shifting

Belt too tight

Difficult to shift

Belt too loose

IMPORTANT

Do not shift the transmission if the engine is off.

174

MAINTENANCE

DRIVEN CLUTCH REMOVAL

To access the Driven Clutch, remove the left side panel.

1. Remove the drive belt. See page 172 for drive belt removal procedure.

2. Lock the parking brake.

NOTICE

If the transmission is in Neutral the driven clutch will spin with the parking

brake on. The transmission must be in High, Low, or Reverse for the parking

brake to stop the driven clutch from spinning.

3. Remove the spare belt holder.

4. Remove the driven clutch bolt

and flat washer

5. Remove the driven clutch assembly

from the jackshaft.

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MAINTENANCE

6. Inspect the jackshaft and driven clutch splines for damage. Replace

components as required.

DRIVE SYSTEM

TRANSMISSION FLUID LEVEL CHECK

The fill plug is located on the right side of the transmission. Access the fill plug
using the following procedure. Maintain fluid level even with the bottom of the fill
plug hole.

1. Position vehicle on a level surface.

2. Remove the right side panel.

3. Remove the push rivets

securing the lower right portion of the console.

176

MAINTENANCE

6. Remove the fill plug

and check the fluid level.

7. For fill specification see page 178. Do not overfill.

8. Reinstall the fill plug and torque to specification.

TORQUE

Transmission Fill Plug:

12 ft-lbs (16 N·m)

TRANSMISSION FLUID CHANGE

The drain plug is located on the bottom of the right side of the transmission.
Access the drain plug using the following procedure.

1. Position vehicle on a level surface.

2. Remove the right side panel.

178

MAINTENANCE

7. Remove the fill plug

8. Place a drain pan under the transmission drain plug.

9. Remove the drain plug

and allow fluid to drain completely.

NOTICE

Fluid may run down the fender before draining into the drain pan. Once fluid

has drained completely, wipe up any residual fluid on the fender.

10. Clean the drain plug magnetic surface.

11. Reinstall the drain plug and torque to specification.

TORQUE

Transmission Drain Plug

12 ft-lbs (16 N·m)

12. Add the recommended amount of fluid through the fill hole. Do not overfill.

FLUID CAPACITY

Transmission Lubricant:

AGL Synthetic Gearcase

Transmission Capacity

23.6 oz (700 mL)

181

MAINTENANCE

13. Reinstall the fill plug and torque to specification.

TORQUE

Transmission Fill Plug

12 ft-lbs (16 N·m)

14. Check for leaks. Dispose of used fluid properly.

TRACK MAINTENANCE

WARNING

Moving parts can cut and crush body parts. When performing the checks and

adjustments recommended on the following pages, stay clear of all moving

parts. Never perform track measurement or adjustments with the engine

running.

TRACK INSPECTION

WARNING

Broken track rods can cause a rotating track to come off the snowmobile,

which could cause serious injury or death. Never operate with a damaged

track. Never rotate a damaged track under power.

NOTICE

The figures below are for reference only. Your model may differ slightly.

1. Using a hoist, safely lift and support

the rear of the snowmobile off the
ground.

2. Rotate the track by hand to check for

damage.

3. Carefully examine the track along

the entire length of each rod

Bend the track to check for
breakage.

4. Replace the track if any rod damage

is found.

182

MAINTENANCE

WARNING

Use of traction products such as studs increases the possibility of track

damage and/or failure. Driving at high speeds for extended periods of time in

marginal lubrication could severely damage track rods, break 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.

TRACK LUBRICATION

The slide rail needs snow for lubrication. Excessive wear indicates insufficient
lubrication. A new rail slide can cause faster heat build-up in limited lubrication,
resulting in excessive wear.

WARNING

Operating with insufficient lubrication between the rail slide and track guide

clips can cause track failure, loss of vehicle control and loss of braking ability,

which can result in serious injury or death. Avoid operating for extended

periods on ice and other surfaces that have little or no snow for lubrication.

If excessive rail slide wear occurs due to poor snow conditions, additional wheel
kits are available. Your authorized POLARIS dealer can provide more
information.

Track damage or failure caused by operation on ice or under other poor
lubrication conditions will void the track warranty.

TRACK TENSION

Track adjustment is critical for proper handling. Always maintain correct tension
and alignment.

TRACK TENSION DATA CHART

SUSPENSION

SLACK

MEASUREMENT

WEIGHT

MEASUREMENT

LOCATION

All Models

7/8-1 1/8 inch

(2.2-2.6 cm)

10 lbs.

(4.54 kg)

16 inches (40 cm)

ahead of rear idler

shaft

TIP

Tension adjustments should be made only after the track is warmed up and

limber.

183

MAINTENANCE

1. Turn the engine off.

2. Lift the rear of the snowmobile and safely support it off the ground.

3. Place the recommended weight or downward pressure on the track at the

specified distance (see chart) ahead of the center of the rear idler wheel.

4. Measure at the point where the weight is hanging.

5. Check for specified slack between the wear surface of the track clip and the

plastic slider. Refer to the Track Tension Data Chart above.

If the track needs adjustment:

6. Loosen the rear idler shaft bolt.

7. Loosen the locknuts.

8. Tighten or loosen the track adjusting screws to provide equal adjustment on

both sides of the track.

9. Repeat the measurement on the other side of the track.

TIP

Check more frequently when the snowmobile is new.

10. Start the engine and slowly rotate the track at least five revolutions. Let the

track come to a stop (do not apply brakes).

11. Check track alignment (see page 185) and adjust as necessary.

12. Tighten the locknuts.

13. Tighten the idler shaft bolt.

TORQUE

Idler Shaft Bolt

35 ft-lbs (47.5 N·m)

184

MAINTENANCE

TRACK ALIGNMENT

Periodically 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 snowmobile with the track off the ground.

2. Start the engine and apply a small amount of throttle until the track turns

slowly at least five complete revolutions. Stop the engine and let the track
come to a stop (do not apply brakes).

3. Inspect track alignment by looking through the track window to make sure

the rails are evenly spaced on each side. If the track runs to the left, loosen
the idler shaft bolt, then loosen the left locknut and tighten the left adjusting
bolt. If the track runs to the right, loosen the idler shaft bolt, then loosen the
right locknut and tighten the right adjusting bolt.

4. After adjustments are complete, tighten the locknuts and torque the idler

shaft bolt to specification.

TORQUE

Idler Shaft Bolt

55 ft-lbs (75 N·m)

5. Repeat steps 2-3 to verify proper alignment.

185

MAINTENANCE

FRONT SUSPENSION INSPECTION

WARNING

Improper fastener torque or front suspension component damage may cause

loss of steering control, resulting in serious injury or death. Your POLARIS

dealer can assist.

Each week, or before a long ride, check the following items. If component
damage or loose fasteners are found, your POLARIS dealer can provide
service.

Ski Bolt Nuts

Tie Rod End Nuts

Upper/Lower Control Arm Nuts (All)

Sway Bar Fasteners

Shock Mounting Fasteners

Lower Control Arm Spindle Nuts

Upper Control Arm Spindle Nuts

Ski Loop Rear Fasteners

Ski Loop Front Fasteners

Ski Skag Fasteners

187

MAINTENANCE

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. Your authorized POLARIS dealer can assist.

To align skis, do the following:

1. Place the handlebars in a straight-ahead position.

2. With only vehicle weight compressing the suspension, measure 10 in (25.4

cm)

forward from the center of the ski mounting bolt. From this point,

measure the distance between the skis

3. Measure 10 in (25.4 cm)

rearward from the center of the ski mounting bolt.

From this point, measure the distance between the skis

4. Measurement

should be 1/8 in (3 mm) greater than measurement

188

MAINTENANCE

SKI SKAGS

WARNING

Worn skis and/or skags will adversely affect handling. Loss of vehicle control

may result, causing serious injury or death. Your dealer's studding chart can

provide the recommended skags. If you install longer or more aggressive

carbide skags than the original equipment, it may also be necessary to add

track studs to maintain proper vehicle control while turning on hard-packed

snow or ice.

Check skags before each use of the snowmobile to ensure positive steering
characteristics. Skags must be replaced when worn to half their original
diameter.

TIP

Carbide skags must be replaced if any abnormal wear or chipping is found.

SKAG REPLACEMENT

To replace a ski skag, do the following:

1. Raise and support the front of the snowmobile so the skis are approximately

6 in (15.2 cm) from the ground.

2. Remove the attaching ski skag fasteners

and pry the skag

downward.

3. Remove the front end of the skag.

4. Remove the rear end of the skag.

189

MAINTENANCE

5. Reverse the steps to install a skag.

6. Torque skag fasteners to specification.

TORQUE

Ski Skag Fasteners

8 ft-lbs (11)

RAIL SLIDE WEAR INSPECTION

Polaris rail slides run along the bottom of the rail to prevent track wear. The rail
slide should be inspected periodically and replaced when necessary.

For ease of inspection, all POLARIS rail slides have a wear limit indicator groove

to indicate the minimum permissible slide thickness

. Replace the rail slides

if they are worn to the top of the groove at any point along their length. Failure to
do so may result in permanent damage to the track or rails.

190

MAINTENANCE

BATTERY

WARNING

CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related accessories can expose you to

chemicals including lead, which is known to the State of California to cause

birth defects or other reproductive harm. For more information go to www.

P65Warnings.ca.gov.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can

result from contact with skin, eyes or clothing. Antidote:

•

External:

Flush with water.

•

Internal:

Drink large quantities of water or milk. Follow with milk of

magnesia, beaten egg, or vegetable oil. Call physician immediately.

•

Eyes:

Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases.

Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in

an enclosed space. Always shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

BATTERY IDENTIFICATION

It is important to properly identify the type of battery installed in your snowmobile
as different battery types require different service procedures. Proper servicing
and battery maintenance is crucial for battery longevity.

The four types of batteries are:

• Lead Acid Conventional
• Dry Shipped Absorbed Glass Mat (AGM)
• Lead Acid Low Maintenance
• AGM Low Maintenance

Refer to the following examples to identify the type of battery in your vehicle.

191

MAINTENANCE

LEAD ACID CONVENTIONAL AND DRY SHIPPED AGM
BATTERIES

These batteries are characterized by the following features:

• Battery is NOT activated when packaged
• Removable cap plugs and strip are found top-side of the battery
•

Lead Acid Conventional batteries ONLY:

–

Distilled water is added, as needed

–

Vent tube is located on the side of the battery

LOW MAINTENANCE BATTERIES

Low maintenance batteries are characterized by the following features:

• Battery is pre-activated when packaged
• Non removable cap(s) is located top-side of the battery
• Distilled water or electrolyte is NEVER added

192

MAINTENANCE

BATTERY REMOVAL

WARNING

Improperly connecting or disconnecting battery cables can result in an

explosion and cause serious injury or death.

When removing the battery, always disconnect the negative (black) cable first.

When re-installing the battery, always connect the negative (black) cable last.

1. Locate and release the 1/4-turn fastener at the back of the seat. Lift to

remove seat.

2. Disconnect the black (negative) battery cable

first.

3. Disconnect the red (positive) cable

last.

4. Remove fasteners

that secure the battery box cover.

5. Remove the battery box cover

6. Remove the battery from the battery box.

193

MAINTENANCE

BATTERY INSTALLATION

When installing a new battery, ensure it has a full charge prior to initial use.
Using a new battery with a partial charge can damage the battery, cause shorter
battery life, and hinder vehicle performance. Follow the charging instructions,
included with your new battery, before installing.

To install a new battery in your snowmobile, do the following:

1. Ensure the battery is fully charged.

2. Set the battery in the battery bracket.

3. Place the battery cover on the battery bracket.

4. Secure the two battery cover screws.

5. Connect and tighten the positive (red) cable

to the positive terminal first.

6. Connect and tighten the negative (black) cable

to the negative terminal

last.

CAUTION

Verify the battery cables and wiring harness do not come into contact with the

brake disc. Move the wiring harness/cables behind the chassis tube and away

from the brake disc.

7. Verify the cables are properly routed.

8. Re-install the seat. Ensure it latches securely.

194

MAINTENANCE

BATTERY CHARGING

WARNING

An overheated battery may explode, causing severe injury or death. Always

watch charging times carefully. Stop charging if the battery becomes very

warm to the touch. Allow it to cool before resuming charging.

To ensure your battery maintains its level of charge, the battery should be
connected to a battery trickle charger using the battery charge port when not in
use. The battery charge port

is located on the back of the seat.

1. Check the battery voltage

with a voltmeter or
multimeter. A fully charged
battery will register 12.8 V or
higher.

2. If the voltage is less than

12.8 volts, recharge the
battery at 1.2 amps or less
until the battery voltage is
12.8 or greater using the
battery charge port.

195

MAINTENANCE

USING A CONSTANT CURRENT CHARGER

When charging the battery using an automatic charger, always refer to the
charger manufacturer's instructions before use.

When using a constant current charger, use the following guidelines:

State of Charge

Voltage

Action

Charge Time*

100%

12.8-13.0 volts

None; check at 3
months from date of
manufacture

None required

75%-100%

12.5-12.8 volts

May need slight
charge. If no charge
given, check in 3
months

3-6 hours

50%-75%

12.0-12.5 volts

Needs charge

5-11 hours

25%-50%

11.5-12.0 volts

Needs charge

At least 13 hours,
verify state of charge

0%-25%

11.5 volts or less

Needs charge with
de-sulfating charger

At least 20 hours

*Using constant current charge at standard amps specified on top of battery.

Always verify battery condition before charging and 1-2 hours after charging.

BATTERY CHARGE RELAY CONTROL

The battery provides power for two purposes:

• Engaging the electric starter motor to start the engine
• Powering the 7S display when the engine is off

The engine management system engages the battery charge relay and charges
the battery only when the following conditions are met:

• Load shed relay is engaged by the engine management system
• Engine speed exceeds 2500 RPM
• Chassis DC voltage exceeds 13 volts

BATTERY MAINTENANCE

Keep battery terminals and connections free of corrosion. If cleaning is
necessary, remove the corrosion with a stiff wire brush and wash with a solution
of one tablespoon baking soda and one cup water. Rinse well with tap water and
dry off with clean shop towels. Coat the terminals with dielectric grease or
petroleum jelly to prevent corrosion.

196

MAINTENANCE

Never store a battery in a partially charged condition or hard, crystal sulfation will
form on the plates resulting in reduced efficiency and shorter service life of the
battery.

If you do not drive the vehicle for more than TWO weeks, maintain Absorbent
Glass Mat (AGM) batteries with the BatteryMINDer® 2012 AGM - 2 AMP
charger (or a similar charger).

BatteryMINDer® 2012 AGM - 2 AMP battery charger

PN 2830438

If you plan to store the vehicle for ONE month or longer, remove the battery from
the vehicle and store in a cool, dry location. Batteries will self-discharge more
rapidly when stored in extreme temperatures. Continue to maintain the battery
with a 2-AMP charger and inspect the battery every 60 days.

BATTERY TYPE

RECHARGE
FREQUENCY

GENERAL MAINTENANCE

Lead Acid
Conventional

Every 30 to 60 days

NEVER add electrolyte to the
battery once the battery is in
service. If necessary, only add
distilled water to the battery.

Dry Shipped AGM

Inspect every 60 days

NEVER add electrolyte or
distilled water to the battery
once the battery is in service.

Lead Acid Low
Maintenance

Every 30 to 60 days

NEVER add electrolyte or
distilled water to the battery.
Doing so will damage the case
and shorten the life of the
battery.

AGM Low
Maintenance

Inspect every 60 days

NEVER add electrolyte or
distilled water to the battery.
Doing so will damage the case
and shorten the life of the
battery.

197

MAINTENANCE

TRANSPORTING THE SNOWMOBILE

Whenever the snowmobile is transported:

1. Be sure the fuel cap and oil cap are installed correctly.

2. Tie the snowmobile to the transporting unit securely using suitable straps.

3. Remove the ignition key to prevent loss.

NOTICE

Use of a cover is recommended when transporting your vehicle on an open

trailer or sled deck. If transporting backward on an open trailer, remove the

windshield before transport.

SUMMER STORAGE GUIDE

TREATING THE FUEL SYSTEM

As the riding season draws to a close, Polaris recommends riders begin treating
their snowmobile’s fuel system with Polaris Carbon Clean or similar
commercially-available fuel stabilizer.

Treating the fuel system with Carbon Clean during the last few rides of the
season ensures the entire fuel system is treated. Then, when it comes time to
store the snowmobile, all the rider has to do is completely fill the fuel tank with
fresh, non-oxygenated fuel and treat the new fuel with Carbon Clean.
It is also recommended riders use non-oxygenated fuel during the last rides of
the season as non-oxygenated fuel stores better than oxygenated fuel and
resists water vapor absorption.
If the rider was unable to treat the fuel system and/or use non-oxygenated fuel at
the end of the riding season, the rider should do the following:

1. The rider should consume as much fuel in the fuel tank as possible during

the last rides of the season.

2. When performing the summerization storage procedures, fill the fuel tank

completely with non-oxygenated fuel. Note that most oxygenated fuels
contain ethanol. Since ethanol is hydroscopic, oxygenated fuel will absorb a
small amount of water vapor during the storage season and more so in
humid locations. Completely filling the tank with non-oxygenated fuel
minimizes water vapor absorption during the storage period and limits the
amount of air and water vapor that can accumulate in the tank.

3. Treat the fuel in the fuel tank with the recommend amount of Polaris Carbon

Clean. The recommended mixing ratio is outlined on the bottle label.

4. Position the snowmobile outside in a well-ventilated area.

5. Start and run the engine for 10-15 minutes to distribute the treated fuel

throughout the fuel system.

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MAINTENANCE

Snowmobile Polaris ProStar S4, Indy XC 129 / 137, Indy Adventure 137, Voyageur 146, Nordic Pro 146. Owner’s Manual (2024) - page 6