Polaris 2015 600 / 800 SWITCHBACK, 2015 600 / 800 RUCH user guide

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2015 600 / 800 RUSH

2015 600 / 800 SWITCHBACK

Snowmobile Owner's Manual

for Maintenance and Safety

IMPORTANT NOTICE TO OWNER

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

code with your smartphone.

Modifications to this snowmobile are not recommended

and may result in voided warranty coverage. Please

read the warranty section of this manual carefully.

WARNING

Read, understand, and follow all of the instructions and safety

precautions in this manual and on all product labels.

Failure to follow the safety precautions

could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth defects

or other reproductive harm.

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

•RZR® sport vehicles

• VICTORY® motorcycles

• GEM® vehicles We believe POLARIS sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine we've ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer® (MSD) technician.

Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

The following are trademarks of POLARIS Industries Inc.:

POLARIS® AXYS™ SWITCHBACK® PERC® RUSH® SWITCHBACK ADVENTURE® LOCK & RIDE®

Copyright 2014 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.

Printed in U.S.A. 2015 600/800 AXYS Snowmobile Owner’s Manual P/N 9925073

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner's manual.

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

This section describes safe vehicle operation and identifies warning labels and their locations.

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

This section identifies the locations of your snowmobile's controls and features.

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 51

This section includes a Suspension Quick Set-Up Guide and explains how to make additional suspension adjustments for the perfect riding experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 66

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

This section explains proper engine break-in, operation of features and general operating procedures.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

This section defines your role, and your dealer's role, in your snowmobile's regular maintenance.

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 137

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 138

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 158

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 171

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

INTRODUCTION

Important Notes for Owners and Drivers

After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold.

Some of the illustrations and photos used in this manual are general representations. Your model may differ.

Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.

You and your dealer must complete the registration form included with your snowmobile and forward it to us. This completed form is necessary to ensure warranty coverage.

Protect and preserve your right to ride by joining your local trail riding clubs.

When teaching inexperienced operators to ride, set up a predetermined course for practice. Make sure they know how to drive and control the snowmobile before allowing them to make longer trips. Teach them proper snowmobile courtesy, and enroll them in driver’s training and safety courses sponsored by local or state organizations.

INTRODUCTION

Preservation of the Environment

POLARIS is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation.

Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment.

Noise Level

One of the most publicized issues about snowmobiles is noise. The Society of Automotive Engineers (SAE), the standard-setting body for snowmobile development, recommends that snowmobiles conform to prescribed sound levels.

POLARIS snowmobiles are engineered to conform to these SAE standards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others. We do our part by manufacturing quieter machines; we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly.

Air Pollution

POLARIS engineers continuously investigate ways to reduce emission levels of two-stroke engines. We expect our efforts to lead to the reduction of potential air pollution.

In addition to our technological research, we encourage government agencies, manufacturers, distributors, dealers, ecologists, and other interested parties to work together to develop data on environmental topics.

INTRODUCTION

Vehicle Identification Numbers

Record your snowmobile's identification numbers and key number in the spaces provided.

NOTE: The Vehicle Identification Number (VIN) is stamped into the side of the

tunnel and printed on the tunnel VIN label.

Certification Label

Tunnel VIN

Vehicle Model Number: ___________________________________________________

Tunnel VIN (right side of tunnel): ____________________________________________

Engine Serial Number (on recoil housing): _____________________________________

Key Number: _____________________ _______________________________________

NOTICE: If installing an aftermarket tunnel wrap, do not cover the tunnel

certification, tunnel VIN or emissions certification labels with the wrap. If the tunnel wrap doesn’t provide an opening for these labels, remove the section of wrap where the labels are located.

Emissions Certification Label

INTRODUCTION

Engine Serial Number

Key Identification

Number

Engine Serial Number

The engine serial number is located on the identification label on the engine recoil cover.

Key Identification

The ignition keys are etched with an identification number. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank using the same identification number with one of your existing keys, so if both keys are lost, the ignition switch assembly must be replaced.

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that could result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

SAFETY

WARNING

Operator Safety

Follow the recommended maintenance program beginning on page 88 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger. They will reduce your alertness and slow your reaction time.

Snowmobiles are capable of traveling at high speeds. Use extra caution to ensure operator safety. Make sure your snowmobile is in excellent operating condition at all times. Always check major and vital safety components before every ride.

All POLARIS snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. DO NOT MODIFY YOUR MACHINE. The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury.

The warranty on your entire machine is terminated if any equipment has been added, or any modifications have been made, to increase the speed or power of the snowmobile.

SAFETY

STEP

Operator Safety

Stay Clear of Track

Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Do not stand on the plastic flap.

WARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track. Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures.

Stay Clear of Engine

Never attempt adjustments with the engine running. Stop the engine before opening a side panel. Always ensure that the hood and side panels are installed and securely latched before starting the engine.

WARNING! Serious injury can occur if fingers or clothing contact the moving parts of an engine. Always stop the engine before attempting adjustments.

Riding Position

Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmobiles, but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.

WARNING! Improper riding position may reduce control and could result in serious injury or death. Always ride in a position that allows for control of your vehicle.

SAFETY

Operator Safety

Riding Apparel

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

051039

0006.31

Clothing

Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 21.

WARNING! Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury. Always wear an approved helmet and eye protection.

SAFETY

Operator Safety

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death.

Survival Preparation

For your safety, always ride in a group of other snowmobilers. Always tell someone where you're going and how long you expect to be gone. If it isn't possible to ride with others, and you must travel into remote areas, always carry survival equipment that's appropriate to the conditions you may encounter. Such equipment may include, but is not limited to: extra clothing, a sleeping bag, a flashlight, food and water, a signaling mirror, a means of building a fire and a two-way radio or cellular telephone.

Always carry the owner’s manual on your snowmobile. For added protection, purchase and carry the following items on your snowmobile as well:

• Spare Drive Belt • Winter Survival Kit

• Extra Set of Spark Plugs • Trail Map

•Tow Rope •First Aid Kit

• Extra Oil • Tool Kit

• Fuel Deicer

SAFETY

Operator Safety

Rider Capacity

This snowmobile is designed for a single rider only. Never carry a passenger on this snowmobile.

Excessive Speed

WARNING! High speed driving, especially at night, could result in serious injury

or death. Always reduce speed when driving at night or in inclement weather.

Always observe all state and local laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling about 60 feet (18 m) per second. If you look back for only two seconds, your snowmobile will travel about 120 feet (36 m). If your speed is 60 MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in two seconds.

Traveling at night requires extra caution. Check headlight and taillight to ensure proper operation, and don’t over-drive your headlight beam. Always be able to bring your snowmobile to a stop in the distance illuminated by the headlight.

SAFETY

Operator Safety

Driver Awareness

Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wires on utility poles are also difficult to distinguish.

Make sure the way is clear before crossing railroads and other roads and highways. The noise of your snowmobile will drown out the sound of approaching vehicles. Look ahead, behind, and to both sides before turning or crossing railroad tracks or highways. Steep embankments may also hide your view. Always leave yourself a way out.

Variances in snow depth and/or water currents may result in uneven ice thickness. You may drown if you break through the ice. Never travel on frozen bodies of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the snowmobile, you and your cargo, together with any other vehicles in your party . Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Snowmobile operators assume all risk associated with ice conditions on frozen bodies of water.

When teaching inexperienced operators to ride, set up a predetermined course for practice. Make sure they know how to drive and control the snowmobile before allowing them to make longer trips. Teach them proper snowmobile courtesy , and enroll them in driver's training and safety courses.

SAFETY

Operator Safety

Avalanches

Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain:

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

• Make sure each person is equipped with a shovel, probe and avalanche beacon.

Y o u don’t have to be snowmobiling on a slope for an avalanche to occur . Be aware that all of the snow is connected. You may be riding on a flat slope or snow covered road, but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you. Always be aware of snow conditions above you as you travel in mountainous terrain.

Before riding in mountainous terrain, call or log on to your local avalanche advisory to get current weather and snow stability information.

For more information about avalanche training and avalanche conditions, contact local law enforcement in your area, or visit the American and Canadian online avalanche centers at www.avalanche.org.

SAFETY

Operator Safety

Ice and Snow Build-up

WARNING! Ice and snow build-up may interfere with the steering of your

snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice.

Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.

Driving on Slippery Surfaces

WARNING! Never attempt an abrupt change of direction when operating on

slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hardpacked snow reduces steering and braking control, which may result in loss of control and serious injury or death. Slow down and use extra caution when operating on slippery surfaces.

Inadequate Snow Conditions

Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile.

NOTICE: Driving in too little snow will result in excessive wear and damage to WARNING! Inadequate cooling and lubrication will lead to overheating of the

slide rail and track, causing premature wear, damage and failure, which can result in serious injury. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating for prolonged periods on ice, hard-packed surfaces or roads.

the slide rail, track and/or engine.

Operating in Deep Snow

If the snowmobile becomes stuck in snow, clear the running board area of snow, then step down the snow in front of the snowmobile so that when the throttle is opened, the snowmobile will be able to climb up and over the snow.

SAFETY

Operator Safety

Driving Downhill

When riding downhill, shift your weight to the rear of the snowmobile and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the snowmobile and keep it from rolling freely downhill.

WARNING! When driving on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, which may result in brake failure. Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system. This condition may lead to a sudden loss of brakes and/or fire and may result in serious injury or death.

Driving in Hilly Terrain

WARNING! Climbing a hill or crossi ng the face of a slope may result in loss of

balance and snowmobile rollover, causing serious injury or death. Use caution and good judgement when driving in hilly terrain.

Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you must cross the face of a slope, keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible roll-over.

Slow down when reaching the crest of a hill. Be prepared to react to obstacles, sharp drops or other people or vehicles that may be on the other side of the hill.

If you’re unable to continue up a hill, turn the snowmobile downhill before it loses momentum. If this isn't possible, spin the track just enough to dig in to prevent it from rolling back down the hill. Stop the engine and set the parking brake (if equipped). Keeping away from the downhill side of the snowmobile, pull the rear of the snowmobile around and point the front end and skis downhill. Remount the snowmobile, restart the engine, release the parking brake, and descend the hill carefully.

SAFETY

Operator 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.

NOTICE: Operation of the engine with the belt removed may result in injury or

Intake Silencer

Do not operate the engine with the intake silencer or filter removed.

NOTICE: Damage to the engine may occur if the intake silencer or filter are

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 balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from ice and snow before attempting to drive. Apply the throttle with enough authority to put the snowmobile into motion, but always operate within safety limits.

damage to the engine.

removed.

Maneuverability

While much control and maneuverability is achieved through the steering system and skis, maximum control is achieved by the shifting of your body weight. Maneuverability will change for lighter operators or snowmobiles designed to carry a load.

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 snowmobile and with what it will and won't do under various conditions. Even seasoned drivers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.

• A snowmobile depends on the rider’s body position for proper balance in executing turns, traversing hills, etc. Always start on a smooth, level area to begin building your operating experience.

• Before allowing someone else to use your snowmobile, know the extent of their operating skills. Check to see if they've taken a snowmobile safety course and have an operator's certificate. For their protection, as well as yours, make sure they take a snowmobile safety course. Everyone can benefit from the course.

• Don't “jump” your snowmobile over large drifts or similar terrain. Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground. The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions. Your snowmobile is not intended for this kind of use.

• Be courteous to oncoming traffic by dimming your headlights and reducing your speed.

• When traveling in a group of snowmobiles, don't tailgate (follow too closely). Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris. Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions. Be aware of any snowmobile traffic around your vehicle. Drive defensively to avoid accidents.

• Remove the key from the ignition when you leave the snowmobile unattended.

SAFETY

Operator Safety

Windchill/Temperature Charts

The following information is provided to help you determine when temperatures become dangerous for riding.

WINDCHILL CHART (°F)

Wind

Speed

40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45

MPH Calm 40 35 30 25 20 15 10 5 0 -5 -10 -15

5 3631251913 7 1 -5-11-16 10 34 27 21 15 9 3 -4 -10 -16 15 32 25 19 13 6 0 -7 -13 20 30 24 17 11 4 -2 -9 -15 25 29 23 16 9 3 -4 -11 -17 30 28 22 15 8 1 -5 -12 35 28 21 14 7 0 -7 -14 40 27 20 13 6 -1 -8 -15 45 26 19 12 5 -2 -9 -16 50 26 19 12 4 -3 -10 -17 55 25 18 11 4 -3 -11 60 25 17 10 3 -4 -11

Frostbite in >>

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

-20 -25 -30 -35 -40 -45

-22 -28 -34 -40 -46 -52 -57 -63

-22 -28 -35 -41 -47 -53 -59 -66 -72

-19 -26 -32 -39 -45 -51 -58 -64 -71 -77

-22 -29 -35 -42 -48 -55 -61 -68 -74 -81

-24 -31 -37 -44 -51 -58 -64 -71 -78 -84

-19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87

-21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89

-22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91

-23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93

-24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95

-18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97

-19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98

30 min. 10 min. 5 min.

WINDCHILL CHART (°C)

Wind

Speed

5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46

Km/h Calm 5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28

8 3 0 -4 -7 -11 -14 -18 -22 -25 -29 16 2 -2 -6 -10 -13 -17 -21 -24 -28 24 1 -3 -7 -11 -15 -19 -22 -26 32 0 -4 -8 -12 -16 -20 -24 -28 40 -1 -5 -9 -13 -17 -21 -25 -29 48 -1 -5 -9 -13 -18 -22 -26 56 -2 -6 -10 -14 -18 -22 -26 64 -2 -6 -10 -15 -19 -23 -27 72 -2 -7 -11 -15 -19 -23 -28 80 -3 -7 -11 -15 -20 -24 -28 88 -3 -7 -12 -16 -20 -24 96 -3 -8 -12 -16 -21 -25

Frostbite in >>

Actual Thermometer Reading (°C)

Equivalent Temperature (°C)

-32 -36 -39 -43 -46 -50 -53 -57

-32 -36 -39 -43 -47 -50 -54 -58 -62

-30 -34 -38 -42 -45 -49 -53 -57 -61 -65

-32 -36 -39 -43 -47 -51 -55 -59 -63 -67

-33 -37 -41 -45 -49 -53 -57 -61 -65 -69

-30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70

-31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72

-31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73

-32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74

-33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75

-29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76

-29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

30 min. 10 min. 5 mi n.

-31 -34 -37 -40 -43 -46

SAFETY

Pressure Cap

Warning

Safety Labels and Locations

W arning labels have been placed on the snowmobile for your protection. Read and follow the instructions of the labels and other warnings on the snowmobile carefully . If any of the labels depicted in this manual differ from the labels on your snowmobile, always read and follow the instructions of the labels on the snowmobile.

If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.

Pressure Cap Warning

This warning label is found on the pressure cap of applicable liquid cooled models:

WARNING Do not open hot. T est or replace

when changing coolant. Press down and turn to release cap. 13 PSI

7170063

Track Warning

WARNING Stay clear of track. Do not sit on

seat back. Entanglement with the track or a fall from seat back may result in severe injury or death.

Track Warning

7175974

Safety Labels and Locations

Reverse Warning

Fuel Recommendation Label

No Passenger

Warning

No Passenger Warning

WARNING This vehicle is designed for

operator only. NO PASSENGER.

7181012

Fuel Recommendation Label

91+ Octane without Ethanol. For maximum performance see decal on left hand side panel for setting.

7181061

Reverse Warning

WARNING Reverse operation, even at low speeds, can cause loss of control

resulting in serious injury or death. To avoid loss of control, always:

• Look behind before and wh ile ba cking up.

• Avoid sharp turns.

• Shift to or from reverse only when stopped.

• Apply throttle slowly. NOTE: For more information, see Owner’s Manual. If electric reverse:

• Machine stopped and engine at idle, push yellow button on LH control to reverse. Flashing light on dash indicates reverse operation.

• Push button again to return to forward.

SAFETY

7176779

SAFETY

Safety Labels and Locations

Operation Warning

WARNING

• To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, contact a POLARIS dealer for a replacement.

• This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control. Reduce speed and use extreme caution when operating in unfamiliar terrain.

• Excessive speed, especially at night or with limited visibility, can result in insufficient time for you to react to terrain changes, to avoid unexpected obstacles, or to stop safely.

• Never consume alcohol or drugs before or while operating this vehicle.

• In an emergency, push down the Auxiliary Shut-Off Switch, located on the top of the throttle control assembly, to stop the engine. Then pull the brake lever to stop.

• Always wear an approved helmet, eye protection, and adequate clothing while operating this vehicle.

• This vehicle is designed for adult use only. Check local laws for age requirements.

• When operating with a passenger (on approved models only) reduce speed and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle.

• When operating on hard-packed snow, ice, or when crossing roads, steering and braking ability are greatly reduced. Reduce speed and allow extra space to turn or stop.

• To maintain vehicle control on ice or hard-packed surfaces, you should have a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products.

• Repeated stops from high speed may cause fading or sudden loss of braking ability.

• Parking brake may relax when used for long periods. Do not leave brake engaged for more than five minutes.

• Before starting engine, check throttle, brake, and steering for pr oper operation. Make sure hood and side panels are latched. Be seated and in position to control the vehicle.

Oil injection system: Use unmixed fuel only. Check oil level when refueling.

Operation Warning

7176779

SAFETY

Clutch Warning/Belt Removal

Safety Labels and Locations

Clutch Warning/Belt Removal

WARNING Do not operate engine with hood or side panels open. Do not attempt

adjustment with engine running. Do not operate engine with the clutch guard removed. Never run engine with drive belt removed. Never service clutches yourself - See your dealer.

Belt Removal - All Units

1. For electric reverse models,

engine must be stopped in forward to allow clutch opening

2. Install L-wrench from fender

into the open threaded hole in the driven clutch.

3. Turn the L-wrench clockwise

to open the sheaves and replace the belt.

4. Return the L-wrench to the

fender.

Note: See owners manual for sheave width adjustment procedure.

7181093

FEATURES

1. Nosepan

2. Skis

3. Front Bumper

4. Hood

5. Headlight

6. Windshield (accessory)

7. Handlebar

8. Operator Seat

9. Taillight

10. Rear Bumper

11. Snow Flap

12. Suspension

13. Track

14. Side Panel

15. Side Panel Fasteners

16. Tool Kit (Inside engine compartment)

17. L-Wrench

FEATURES

1. Brake Lever

2. Instrument Cluster (Interactive Digital Display shown)

3. Ignition Switch

4. Engine Stop Switch

5. Throttle Control

6. Recoil Starter Handle

7. Parking Brake Lock

8. Handlebar Grip Warmer Switch

9. Thumbwarmer Switch

10. POLARIS Electronic Reverse (PERC) Button

11. Mode/Set Switch

12. Headlight Dimmer Switch

FEATURES

2 in. (5 cm)

Lamp Center Height

25 ft. (7.6 m)

Adjustable Headlight

The headlight can be adjusted for vertical aim using the following procedure.

1. In a well-ventilated area, position the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wall.

2. Place the rider or the approximate weight of the rider on the seat or tunnel floorboards.

3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

4. Start the engine. Move the headlight switch to high beam.

5. Observe the headlight aim on the wall. The most intense part of the headlight beam should be two inches (5 cm) below the mark on the wall.

6. If adjustment is necessary, access the headlight adjuster knob through the left side panel. Turn the adjuster knob clockwise to lower the beam. Turn the adjuster counterclockwise to raise the beam.

Raise

Lower

Heated Storage Compartment

Heated Storage

(if equipped)

The storage compartment on the top of the console is heated by engine compartment heat. This compartment can be used to warm gloves or defog goggles.

12-Volt Receptacle

If equipped, the 12-volt DC receptacle is located on the console next to the instrument cluster. If not equipped, the receptacle can be installed as an accessory.

The 12-volt receptacle is protected by a 2 AMP fuse.

FEATURES

12-Volt Receptacle

(if equipped)

FEATURES

Saddlebags

Some snowmobiles are equipped with saddlebags. LOCK & RIDE saddlebags can be added as an accessory on other models. Please see your POLARIS dealer for more information.

Three (3) locking plungers secure each saddlebag to the rear cargo rack. To remove a saddlebag, open each plunger latch, then pull the bag away from the rack.

When reinstalling the saddlebags, always make sure the locking plungers are secured before operating.

FEATURES

Fuel

Selection

Fuel Type Selection

Whenever using ethanol, MTBE or other forms of oxygenated gasoline, the fuel type designation setting must be changed to “Eth” in the gauge. When using the recommended 91 non-ethanol gasoline, always select the “91-non” setting. Whenever in doubt of your fuel purchase, use the

“Eth” setting as a safeguard.

Interactive Digital Display (IDD)

If your model is equipped with the interactive digital display (IDD), please see your IDD Owner’s Manual for fuel type selection procedures.

Standard Instrument Cluster

Use the following procedure to change the fuel type designation in the standard instrument cluster. Refer to the fuel type selection label located

inside the left side panel.

Fuel Type Selection Label

1. Start the engine. Lock the parking brake.

2. Press and release the SELECT button or SET switch until “FUEL” is displayed in the lower section of the gauge.

3. Press and hold the SELECT button or SET switch until the desired fuel type is displayed in the center of the screen.

Step 2 Step 3

FEATURES

Standard Instrument Cluster

Interactive Digital Display (IDD)

Detonation Elimination Technology (DET)

The DET system prevents damage to the engine from detonation by entering an engine protection mode whenever the DET system is active.

When excessive detonation is detected, the check engine light will illuminate. You may notice decreased engine performance and RPM when the DET system is activated. In most cases this is temporary and no action is required. The engine will return to its normal performance automatically.

If severe detonation occurs, the check engine light will begin to flash steadily.

• The standard gauge will display “dET”.

• The IDD will display “Detonation Detected - MAG (or PTO)”. The engine will enter a limp home mode and engine speed will be

limited to 6500 RPM. The engine will remain in this mode until it is shut down and restarted.

Check Engine Light Indicates

Solid or Flickering Excessive detonation detected

Steady Flashing Severe detonation detected, RPM will be limited

FEATURES

Detonation Elimination Technology (DET)

The most likely causes of severe detonation are outlined in the troubleshooting table below.

DET Troubleshooting

Cause of DET Activation Solution

Poor quality fuel Replace with higher quality fuel Incorrect ethanol/non-ethanol fuel

type setting Low fuel/no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel filter or tank pick-up sock See your POLARIS dealer for service Alcohol-based fuel additive used with

Ethanol fuel Improper engine modifications Do not modify the engine

Verify correct fuel type setting on gauge

Do not add deicers or additives that contain any form of alcohol while using up to 10% ethanol fuel

FEATURES

Engine Overheat Indicators

Over-Temperature Indicator (Standard Cluster)

The over-temperature indicator on the standard instrument cluster will illuminate when the engine is overheating. Take action to cool the engine. See page 35.

The indicator will flash when engine temperature reaches critical levels. Stop the engine immediately.

Overheat Warning (IDD)

The engine temperature scale at the right side of the IDD screen changes to RED and the check engine temperature indicator at the top left of the screen illuminates when the engine is overheating. Take action to cool the engine. See page 35.

The indicator will flash when engine temperature reaches critical levels.

Stop the engine immediately.

Please see your IDD Owner’s Manual for more information.

Flashing Indicator

Flashing indicators indicate continued operation could result in serious engine damage. The engine management system will automatically reduce engine power and create a misfire condition. Stop the engine immediately. Allow the engine to cool down.

NOTE: If engine overheating seems to be caused by something other than

poor cooling conditions, see your dealer for service.

FEATURES

Engine Overheat Indicators

Engine-Cooling Actions

If the engine is overheating, promptly take action to cool the engine.

• Drive in loose snow.

• V iew the coolant level. Do not open the pr essur e cap while the engine

is hot. Add coolant if the level is low.

• Stop the engine and allow it to cool down.

NOTICE: If you must continue to operate while the indicator light is illuminated,

Security System (Ignition Lock System)

Your snowmobile has an optional security function that can be activated by an authorized POLARIS dealer. If you have this feature activated, you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended. A locked system will limit engine speed to 3000 RPM, which prevents clutch engagement, and the snowmobile will not move when throttle is applied.

If you wish to use this system, see page 43 for security system activation and operating instructions (standard instrument cluster). If your model is equipped with the Interactive Digital Display (IDD), please see the IDD Owner’s Manual provided with your snowmobile.

drive slowly and stop the engine frequently to allow it to cool down.

FEATURES

Rider Information

Center

Check Engine

Indicator

High Beam

Indicator

Low Oil

Indicator

Over-Tem-

perature Indi-

cator

Parking Brake

Indicator

Reverse

Indicator

MODE Button

SELECT

Button

Standard Instrument Cluster

The instrument cluster contains indicator lights and the rider information center. The information center can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the MODE/ SET switch on the left handlebar.

NOTICE: Certain products will damage

CAUTION! The speedometer may give wrong values at the existence of

electromagnetic radiation >= 10 V/m.

the lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Immediately clean off any gasoline that splashes on the instrument cluster.

MODE SET

FEATURES

Standard Instrument Cluster

Indicators

Check Engine Indicator

This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning appears. Serious engine damage could result. See your dealer. See page 92 for diagnostic code definitions.

Over-Temperature Indicator

This indicator illuminates to alert the operator that the engine is overheating. The operator should take action to cool the engine. If the indicator flashes, continued operation could result in serious engine damage. Stop the engine immediately.

Low Oil Indicator

The low oil indicator light may flicker at times due to oil movement in the bottle, but when the light comes on and remains on, add the recommended oil before further operation. See page 80.

High Beam Indicator

The high beam indicator illuminates when the lights are set to high beam.

Parking Brake Indicator

This indicator illuminates when the parking brake is engaged. It will also illuminate when the service brake is in use. See page 70.

Reverse Indicator

This indicator flashes when the snowmobile is in reverse. See page 85.

FEATURES

Standard Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine temperature and diagnostic display mode.

Setting changes must be made with the engine running or with the vehicle powered by an external DC power supply connector.

The information center is set to display standard units of measurement for distance and temperature. To change to metric units, see page 42.

FEATURES

Standard Instrument Cluster

Rider Information Center

1. Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. To change the display, see page 40.

2. Speed Display - The speed display area displays either vehicle speed or engine speed. To change the display, see page 40.

3. Fuel Gauge - The segments of the fuel gauge show the level of fuel

in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the

fuel sensor circuit. See your dealer.

4. Odometer/Engine Hour Display - This area displays the odometer,

Trip A, Trip B and engine hours. To change the display, see page 41.

5. Battery Power - This indicator illuminates when battery power is

low.

6. Playback Icon - The playback function allows the rider to record

and play back engine speed, vehicle speed and throttle position sensor information for up to three minutes. The playback icon flashes while recording. See page 41.

FEATURES

Standard Instrument Cluster

Rider Information Center

Speed Display Area

The speed display area displays either vehicle speed or engine speed. Vehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM).

1. To change which item displays, first make sure the information display area is set to display either engine speed or vehicle speed.

2. Press and hold the MODE button (on the instrument cluster) or the MODE switch (on the left handlebar) for three seconds.

Information Display Area

This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. To change the display, press and release the MODE button or the MODE switch until the desired item is displayed.

FEATURES

Standard Instrument Cluster

Rider Information Center

Odometer/Engine Hour Display Area

This area displays the odometer, Trip A meter, Trip B meter and engine hours meter.

The odometer displays the total distance traveled by the vehicle since manufacture. Each trip meter records the distance traveled by the vehicle on a trip if the meter is reset before each trip. The engine hour meter displays the total hours the engine has been in operation since manufacture.

T o change the display, pr ess and release the SELECT button or the SET switch until the desired item is displayed.

To reset a trip meter, press and hold the SELECT button or the SET switch until the meter resets to zero.

Playback Function

The playback function allows the rider to record and play back engine speed, vehicle speed and throttle position sensor information for up to three minutes.

1. To begin recording, simultaneously press and hold the MODE and SELECT buttons on the instrument cluster for three seconds. The playback indicator will flash while the instrument cluster is recording.

2. To play back the recorded data, stop the vehicle and wait for engine speed to drop below clutch engagement.

3. Simultaneously press and release the MODE and SELECT buttons on the instrument cluster.

4. Applying the throttle will clear the display and return the instrument cluster to normal operation.

FEATURES

Standard Instrument Cluster

Rider Information Center

Standard/Metric Display

The odometer and temperature displays can be viewed in either standard or metric units of measurement. Both displays change if units are changed. The new settings will remain until changed by the operator.

Change Method 1

1. Press and release the MODE button or MODE switch until engine temperature displays.

2. Press and hold the MODE button or MODE switch until the units

change.

Change Method 2

1. Press and release the SELECT button or SET switch until the odometer displays.

2. Press and hold the SELECT button or SET switch until the units

change.

FEATURES

Standard Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer. If you have this feature activated, you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended. A locked system will limit engine speed to 3000 RPM, which prevents clutch engagement, and the snowmobile will not move when throttle is applied.

If you wish to use this feature, you must complete all four tasks on the following pages to have your system activated and to change the security code to one of your own choosing.

FEATURES

Standard Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

First Time Use of Your Security System

Perform all tasks in the order shown if you wish to activate and use the optional security system.

TASK 1: Activate the security system

See your authorized POLARIS dealer to have the optional security system feature activated in the electronic control unit (ECU).

TASK 2: Lock the System the First Time

1. Start the engine and lock the parking brake.

2. Press and hold the MODE and SEL buttons for 3 seconds, then release. SECURE OFF should be displayed. If not, repeat this step.

3. Wait until ENTER CODE displays, then press and release SEL to advance the digit. When “0” is displayed, press and release MODE to accept the digit. TIP: If the ENTER CODE screen exits due to inactivity, repeat step 2.

4. Press and release SEL to advance the second digit. When “0” is displayed, press and release MODE to accept the digit.

5. Press and release SEL to advance the third digit. When “0” is displayed, press and release MODE to accept the digit.

6. After accepting the third digit, view the display screen. SECURE ON displays if the system locks.

NOTE: Th e system is now locked.

7. You must now unlock the system. Proceed immediately to TASK 3.

FEATURES

888

Standard Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

First Time Use of Your Security System

TASK 3: Unlock the System

1. When the engine is running, the display will

alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL to advance the digit. When “0” is displayed, press and release MODE to accept the digit.

2. Press and release SEL to advance the second

digit. When “0” is displayed, press and release MODE to accept the digit.

3. Press and release SEL to advance the third digit.

When “0” is displayed, press and release MODE to accept the digit.

4. After accepting the third digit, view the display

screen. SECURE OFF displays if the system unlocks.

NOTE: Th e system is now unlocked.

5. You must now enter a new security code. Proceed immediately to TASK 4.

TASK 4: Enter Your New Security Code

1. Immediately after locking and unlocking the system, and while SECURE

OFF is displayed, press and release the MODE button to bring up the ENTER CODE screen.

2. When ENTER CODE displays, use the SEL and MODE buttons to select

and accept each digit of a new personal security code.

3. After accepting the third digit, view the display

screen. The new code and CODE SET will display if the system accepted your new code. You will not see this display again.

NOTE: Your new code is now set. The system is

4. Record your new security code in a safe place for future reference.

NOT locked.

Record your new personal security code here: __________________

TIP:If you lose your personal security code, see your dealer to have the code

reset to “000”. Then perform T ASK 2 through TASK 4 to change the code to one of your own choosing.

FEATURES

Standard Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

Locking the System With Your Personal Security Code

1. Start the engine and lock the parking brake.

2. Press and hold the MODE and SEL buttons for 3 seconds, then release. SECURE OFF should be displayed. If not, repeat this step.

3. Wait until ENTER CODE displays, then press and release SEL to advance the digit. When the first digit of your security code is displayed, press and release MODE to accept the digit.

TIP:If the ENTER CODE screen exits due to inactivity,

repeat step 2.

4. Continue to use SEL and MODE to select and accept the remaining two digits of the code.

5. After accepting the third digit, view the display screen. SECURE ON displays if the system locks. Engine speed is now limited and the snowmobile cannot be driven.

TIP:When the engine is running, the display will

alternate between SECURE ON and ENTER CODE.

6. If BAD CODE displays, the screen will then return to the ENTER CODE screen. Repeat steps 3-5 to re-enter the security code.

FEATURES

Standard Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

Unlocking the System With Your Personal Security Code

1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL to advance the digit. When the first digit of your security code is displayed, press and release MODE to accept the digit.

TIP:When the system is locked and engine temperature is above 120° F (49°

C), the correct password must be entered within 60 seconds or the engine will shut down.

2. Continue to use SEL and MODE to select and accept the remaining two digits of the code.

3. After accepting the third digit, view the display screen. SECURE OFF displays if the system unlocks.

4. Re-enter your code if BAD CODE displays.

NOTE: The system is now unlocked.

FEATURES

Standard Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

Changing to a New Security Code

Any time you wish to change your current security code to a new code, perform TASK 2 through TASK 4 of the First Time Use of Your Security System procedure beginning on page 44. Instead of using the factory default code “000” in TASK 2 and TASK 3, use your current security code.

Security System Access Quick Reference

Now that you have become familiar with the procedure for locking and unlocking the system, use the chart below as a quick reference.

Security System Access Quick Reference Chart

Action Result

Start engine + Lock parking brake + Press and hold both MODE + SELECT (SEL)

Press SELECT (SEL) Advances a digit on the ENTER CODE screen Press MODE Accepts a digit and displays the next digit position (if

Displays ENTER CODE (to lock the system)

any remain) on the ENTER CODE screen or Opens ENTER CODE screen if MODE is pressed

immediately after locking and unlocking the system (to change your security code)

FEATURES

Standard Instrument Cluster

Rider Information Center

Diagnostic Display Mode

The diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs.

The diagnostic mode is accessible only when the check engine warning indicator is illuminated and a diagnostic code is active.

Do not stop the engine if you want to view the active code (failure code). Active codes cannot be retrieved if power is interrupted to the instrument cluster. The codes will become inactive codes if power is interrupted. Inactive codes are stored in the history of the unit. Please see your POLARIS dealer to retrieve inactive codes.

Use the following procedure to view active codes.

1. Do not stop the engine.

2. With the brake engaged, press and release the SELECT button or

SET switch to toggle to the diagnostic display mode. When a code is active, the diagnostic display mode will appear immediately following the engine hour display.

TIP:When the diagnostic mode is displayed, the check engine warning indicator

will begin to flash.

3. A set of two numbers will appear in the display.

• The 2-6 digit suspect parameter number (SPN) in the information display

area indicates which component is generating the fault code.

• The 1-2 digit failu re mode indicator (FMI) number in the odometer area

indicates the fault mode, such as open or short circuit.

4. More than one fault may be active. Press and hold the MODE button or MODE switch for two seconds to toggle to the next active code. Repeat until all codes are retrieved.

5. See page 92 for code definitions and failure descriptions.

FEATURES

MODE

SET

Interactive Digital Display (IDD)

5-Button

Keypad

Display

Screen

The Interactive Digital Display (IDD) provides the rider with:

• Speedometer • 2 Trip Meters • Battery Voltage

• Tachometer • Fuel Level Indicator • Fuel Type Selection

• Odometer • Coolant Temperature • Vehicle Security

The IDD also offers GPS mapping and Bluetooth compatible smartphones/devices. This feature will display text messages and missed phone calls on the display screen.

® connectivity for

The IDD sub-menus and most display features are controlled by either the five button keypad on the IDD or by the MODE/SET switch on the left handlebar.

Please see your IDD Owner’s Manual for more information.

NOTICE: Use a microfiber hand towel to clean the LCD screen. Certain

CAUTION! The speedometer may give wrong values at the existence of

electromagnetic radiation >= 10 V/m.

products will damage the screen and other plastic surfaces. Do not use alcohol to clean the display screen. Immediately clean off any gasoline that splashes on the instrument cluster.

THE PERFECT FIT

Suspension Quick Set-Up Guide

Introduction

The front suspension and PRO-XC rear suspension on your AXYS snowmobile is incredibly easy to adjust. Just remember three simple steps:

1. Ride your snowmobile!

2. Adjust the rear track shock spring to tune vehicle balance (ski pressure and weight transfer).

3. Adjust shock clickers to tune ride quality (stiffer or softer ride).

Step 1: Ride your snowmobile!

Ride the snowmobile in various terrain to fully experience the existing suspension settings before making any adjustments.

Step 2: Adjust the rear spring to tune vehicle balance.

After riding the snowmobile, you should be able to determine if the snowmobile needs more “bite” or needs to be more “lite”. If the steering needs more “bite”, increase the rear track spring preload or decrease the front track spring preload.

If you prefer your snowmobile has lighter steering, decrease the rear track spring preload or increase the front track shock spring preload.

At the front of the snowmobile, if you prefer a taller ride height, increase the front suspension shock spring preload settings. Likewise, if you prefer your snowmobile has a lower ride height, you can decrease the front suspension shock spring preload settings.

Step 3: Adjust shock clickers for ride quality.

You can adjust the shock clickers to control bottoming and adjust ride comfort. Turning a clicker counter-clockwise decreases damping for a softer ride. Turning a clicker clockwise increases damping for a stiffer ride and less bottoming.

NOTICE: Always adjust the clicker at least one click below full stiff (full

clockwise) or shock damage will occur.

Test ride the snowmobile and continue making spring and clicker adjustments until you achieve the perfect ride.

THE PERFECT FIT

REAR TRACK SHOCK FRONT (IFS) SHOCKS

FRONT TRACK SHOCK

MORE LITE MORE BITE

Suspension Quick Set-Up Guide

Ride Experience Table

Ride Experience Adjustment

Too “LITE”

•Ski pressure is too light

•Skis push

Too much “BITE”

•Ski pressure is too heavy

•Steering is heavy

Front Suspension (IFS Shocks): Too Stiff Too Soft

Ride Comfort Under Feet (Front Track Shock): Too Stiff Too Soft

Rear Suspension (Rear Track Shock): Too Stiff Too Soft

Shock Locations

Increase rear track shock spring preload OR Decrease front track shock spring preload

Decrease rear track shock spring preload OR Increase front track shock spring preload

(IFS Shocks) Turn clickers 2 clicks SOFT Turn clickers 2 clicks HARD

(Front Track Shock) Turn clicker 2 clicks SOFT Turn clicker 2 clicks HARD

(Rear Track Shock) Turn clicker 2 clicks SOFT Turn clicker 2 clicks HARD

THE PERFECT FIT

Suspension Quick Set-Up Guide

Front Suspension (IFS) Factory Spring Settings

Spring Setting

Model Spring Rate Preload

N/mm in cm in cm in cm

lb/in

RUSH PRO-S 80 RUSH PRO-X 100 SWITCHBACK

PRO-S SWITCHBACK

PRO-X SWITCHBACK

ADVENTURE SWITCHBACK

ADVENTURE (International)

17.5 4-1/2 11.4 4-1/2 11.4 4 3/4 12 7041576

100

17.5 4-1/2 11.4 4-1/2 11.4 4 3/4 12 7041576

100

(Factory

Setting)

14 2-1/2 6.4 2-1/2 6.4 3-1/2 8.9 7043732

CAUTION! Never exceed the minimum/maximum spring preload settings. Always remove the vehicle weight from the spring prior to making adjustments.

Front Suspension (IFS) Factory Clicker Settings

Preload

(Minimum

Setting)

Preload

(Maximum

Setting)

Spring

Part

Number

Model Clicker Setting

(from full soft)

All PRO-S Models 3 All PRO-X Models 6 SWITCHBACK ADVENTURE 3 SWITCHBACK ADVENTURE

(International)

THE PERFECT FIT

Suspension Quick Set-Up Guide

Front (IFS) Shock Adjustments

STIFFER

LOWER

TALLER

SOFTER

THE PERFECT FIT

Suspension Quick Set-Up Guide

Front Track Shock Factory Spring Settings

Spring Setting

Model Spring Rate Preload

N/mm in cm in cm in cm

lb/in

RUSH PRO-S 95-280 RUSH PRO-X 150 SWITCHBACK

PRO-S SWITCHBACK

PRO-X SWITCHBACK

ADVENTURE SWITCHBACK

ADVENTURE (International)

16.6-49 1-1/2 3.8 1-1/2 3.8 1.85 4.7 7043957 26 1 2.54 1 2.54 1-1/4 3.17 7043678

16.6-49 1-1/2 3.8 1-1/2 3.8 1.85 4.7 7043957

95-280

150

95-280

150

26 1 2.54 1 2.54 1-1/4 3.17 7043678

16.6-49 1-1/2 3.8 1-1/2 3.8 1.85 4.7 7043957

26 1 2.54 1 2.54 1-1/4 3.17 7043678

(Factory

Setting)

CAUTION! Never exceed the minimum/maximum spring preload settings.

Always remove the vehicle weight from the spring prior to making adjustments.

Front Track Shock Factory Clicker Settings

Preload

(Minimum

Setting)

Preload

(Maximum

Setting)

Spring

Part

Number

Model Clicker Setting

(from full soft)

All PRO-S Models 3 All PRO-X Models 6 SWITCHBACK ADVENTURE 3 SWITCHBACK ADVENTURE

(International)

THE PERFECT FIT

Suspension Quick Set-Up Guide

Front Track Shock Adjustments

SOFTER

MORE LITE

MEASURE HERE

STIFFER

MORE BITE

THE PERFECT FIT

Suspension Quick Set-Up Guide

Rear Track Shock Factory Spring Settings

Spring Setting

Model Spring Rate Preload

N/mm in cm in cm in cm

lb/in

RUSH PRO-S 120 RUSH PRO-X 150 SWITCHBACK

PRO-S SWITCHBACK

PRO-X SWITCHBACK

ADVENTURE SWITCHBACK

ADVENTURE (International)

Optional HD Spring - RUSH / SWITCHBACK PRO-S ONLY (Rider Weight Range = 200-350 lbs (90-160 kg)

PRO-S (Heavy) 150

120

150

120

150

(Factory

Setting)

21 2-3/4 7253-1/28.9 7041575 26 1-1/2 3.8 1/2 1.2 2-1/2 6.4 7043160 21 2-3/4 7253-1/28.9 7041575

26 1-1/2 3.8 1/2 1.2 2-1/2 6.4 7043160

21 2-3/4 7253-1/28.9 7041575

26 1-1/2 3.8 1/2 1.2 2-1/2 6.4 7043160

CAUTION! Never exceed the minimum/maximum spring preload settings. Always remove the vehicle weight from the spring prior to making adjustments.

Preload

(Minimum

Setting)

Preload

(Maximum

Setting)

Spring

Part

Number

Rear Track Shock Factory Clicker Settings

Model Clicker Setting

All PRO-S Models 3 All PRO-X Models 6 SWITCHBACK ADVENTURE 3 SWITCHBACK ADVENTURE

(International)

(from full soft)

THE PERFECT FIT

Suspension Quick Setup Guide

Rear Track Shock Adjustments

SOFTER

STIFFER

MORE LITE

MORE BITE

THE PERFECT FIT

Suspension Quick Setup Guide

Limiter Strap Adjustment

The front torque arm limiter strap is set at position #1.

MORE BITE

MORE LITE

POLARIS recommends leaving the limiter strap length at position #1 to maintain the optimum ride characteristics of the snowmobile. Riders who desire less ski pressure and more weight transfer toward the rear of the snowmobile can lengthen the limiter strap by changing to position #2.

1. Loosen the lock nut.

2. Adjust the limiter strap.

3. Tighten the lock nut.

Torque: 17 ft-lbs (23 Nm).

THE PERFECT FIT

PRO-S Models - 0° PRO-X Models - 11° Forward

Handlebar Adjustments

Riser Angle

Riser angle can be adjusted to suit rider preference. Factory settings are shown below.

1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver.

2. Adjust the riser forward or rearward to the desired position.

3. Tighten the bolts to 14.8 ft-lbs (20 Nm).

THE PERFECT FIT

PRO-S Models - 30° PRO-X Models - 30°

Handlebar Adjustments

Handlebar Angle

Handlebar angle can be adjusted to suit rider preference. Factory settings are shown below.

1. Loosen the four bolts on the top riser block.

2. Adjust the handlebar upward or downward to the desired angle. Be sure the handlebar, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right. If necessary, loosen the set screws for the left and right controls, rotate the controls slightly, then tighten the set screws to the proper torque. See page

62.

NOTICE: Do not stretch wires while adjusting the controls. Stretching the wires

could damage the handwarmers.

3. Tighten the bolts.

Torque: 14.8 ft-lbs (20 Nm)

THE PERFECT FIT

Handlebar Component Fastener Torques

Shown with riser cover removed for clarity

Component Torque

1. Left Handlebar Control Block 20 in-lbs (2.3 Nm)

2. Brake Lever / Master Cylinder 70 in-lbs (7.9 Nm)

3. Hand Guard Mounts (if applicable) Hand-Tight

4. Upper / Lower Riser Clamps 14.8 ft-lbs (20 Nm)

5. Auxiliary Engine Stop Switch Set Screw 12 in-lbs (1.4 Nm)

6. Throttle Lever Block Set Screw 27 in-lbs (3.1 Nm)

7. Throttle Lever Block Cover Screws 6 in-lbs (0.7 Nm)

8. Riser -

6/7

Do not over-tighten

THE PERFECT FIT

Handlebar Component Locations

Refer to the following illustration and measurements to position handlebar components at factory-specified locations.

Handlebar Component Alignment Measurements

1. .011 in. (3 mm)

2. 6.65 in. (169 mm)

3. 6.7 in. (170 mm)

4. 10 in. (254 mm)

5. .47 in. (12 mm)

6. .08 in. (2 mm)

THE PERFECT FIT

Traction Products

Studs

The track is not warranted by POLARIS if studs have been installed. Track warranties are also void if track damage or failure results from the use of any non-POLARIS traction products. Use only POLARISapproved traction products on your snowmobile.

If you choose to install studs, stud length must not exceed 1.325 inches (3.7 cm) for a factory-installed track.

See your dealer about installing studs and/or carbides.

NOTICE: Use of studs longer than the recommended length on snowmobiles

Track studding will enhance braking control on hard-packed snow or ice, but extreme caution is still required on such surfaces. Steering ability may be reduced on hard-packed snow or ice.

When studded tracks are used, increased wear to the brake pads will result from increased braking and requires increased brake inspection intervals.

Installing studs can also cause the track to stretch more than a nonstudded track. For this reason, POLARIS recommends inspecting track tension more often and setting the tension at the preferred measurement.

Always adhere to the manufacturer’s stud maintenance procedures and stud nut torque specifications.

NOTICE: Aggressive studding patterns may require grinding protruding stud

Before equipping your snowmobile with traction products, be aware of regulations pertaining to the use of traction products in your area of operation.

equipped with center coolers will result in center cooler damage or damage to the tunnel.

bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the specification to prevent heat exchanger damage. The center of the stud must be at least 1 1/8 inch (2.9 cm) from the outside edge of the track.

THE PERFECT FIT

Traction Products

Carbide Skags

A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper steering and control. See page 125.

Maintain a proper balance between the number of studs and the length of carbide on the skags (the more studs you use, the longer the carbide on the skags should be). See your dealer's track studding chart.

Wear Strips

Your snowmobile is equipped with integrated stud protection that will protect the cooling system and tunnel when using a maximum stud length of 1.325 inches (3.7 cm) for all tracks.

See your dealer’s studding chart for recommended traction accessories.

PRE-RIDE INSPECTIONS

Pre-Ride Checklist

Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages.

Item See Page

Drive Belt Condition 115 Steering System 71 Recoil Rope 71 Coolant Level 105 Chaincase Oil Level 98 Injection Oil Level 80 Parking Brake Lock/Brake Lever/Brake System 69, 70, 110 Auxiliary Shut-Off Switch (Engine Stop Switch) 72 Ignition Switch 72 Headlight/Taillight/Brake Light 72 Suspension Mounting Bolts 67 Skags (Wear Bars) 125 Ski Saddle and Spindle Bolts 67 Hood and Side Panel Fasteners 94-95 Throttle Lever / Throttle Release Switch 81, 82 Rear Wheel Idler Bolts 121 Tether Switch/Strap (if equipped) 72 Track Alignment/Condition 71, 122 Rail Slide Condition 128

PRE-RIDE INSPECTIONS

Pre-Ride Suspension Inspection

Loose nuts and bolts can 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.

Item See Page

Check suspension mounting bolts for tightness. See Dealer Check rear idler wheel bolts for tightness. 121 Check rear idler adjusting bolt locknuts for tightness. -Check front torque arm limiter strap condition. -Check rail slide condition. 128 Check track tension. 120 Check ski runner/skag condition. 125 Check ski spindle bolts for tightness. 123 Check tie rod end nuts for tightness. --

PRE-RIDE INSPECTIONS

Before Starting the Engine

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation.

WARNING! Operating the vehicle with worn, damaged, or malfuncti oning components could result in serious injury or death. Never start the engine without checking all vehicle components to be sure of proper operation.

Read and Understand Your Owner's Manual

Read the Owner’s Manual completely and refer to it often. The manual is your guide to safe and enjoyable snowmobiling experience.

Throttle Lever

The throttle and brake are the primary controls of your snowmobile. Always make sure both are functioning properly.

Squeeze the throttle lever to make sure it compresses evenly and smoothly. When released, the lever should immediately return to the idle position without binding or hesitation. If the throttle does not function smoothly, or if you discover excessive lever freeplay, DO NOT start the engine. Have the throttle serviced immediately.

Throttle Release Switch

T est the throttle release switch system before operating the snowmobile. See page 81.

PRE-RIDE INSPECTIONS

10 mm MIN

8 mm MAX

Before Starting the Engine

Brakes

Always check the following items for proper operation before starting the engine.

Brake Lever Travel

NOTICE: Do not pump the brake

Squeeze the brake lever. It should move no closer to the handgrip than 1/2 inch (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 112 or see your dealer for service.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See page 111.

WARNING! Continued use of “spongy” brakes may cause a complete loss of brakes, which could result in serious injury or death. Always have the brakes serviced at the first sign of sponginess.

lever when performing this procedure.

1/2” (1.3 cm)

Brake Fluid Level

Position the handlebars so the brake fluid reservoir is as close to level as possible.

View the fluid level through the reservoir (shaded in illustration). If the level is below the MIN (minimum) level specification, add POLARIS DOT 4 brake fluid. See page 111.

PRE-RIDE INSPECTIONS

Before Starting the Engine

Parking Brake Lever Lock

Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less.

1. Brake Lever

2. Fluid Level Indicator

3. Master Cylinder Reservoir/Cover

4. Parking Brake Lever Lock

Lock Engagement

T o engage the lock, squeeze the brake lever tightly and push forward on the lock. Hold the lock forward while releasing the brake lever.

TIP:If the brake lever is squeezed tightly enough, the lock will move freely into

place. Do not force the lock or it may break.

The parking brake light will illuminate if the parking brake lever lock is set while the engine is running. It will also illuminate when the service brake is in use. If the parking brake light does not come on when the parking brake or service brake is in use, have it serviced by your dealer.

Lock Release

To release the lock, squeeze the brake lever tightly. The lock will return to the unlocked position.

WARNING! If the parking brake lever lock is partially or entirely engaged while riding, the brakes may overheat, resulting in brake damage. In extreme cases it could cause a fire, which could result in serious injury or death. Always ensure that the lever lock is completely disengaged before operating the snowmobile.

PRE-RIDE INSPECTIONS

Before Starting the Engine

Steering System

WARNING! Ice and snow build-up may interfere with the steering of your

snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice.

Track

Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty.

WARNING! Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle.

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.

Side Panel Fasteners

The side panels of the snowmobile protect the operator from moving parts. Never operate the engine with the side panels open or removed.

Recoil Rope

Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your POLARIS dealer for replacement.

PRE-RIDE INSPECTIONS

St art the Engine and Check

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Before Starting the Engine beginning on page 68.

Auxiliary Engine Stop Switch

Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting.

Ignition Key Switch

Make sure the engine stops when the ignition key switch is turned to OFF.

Tether Switch (if equipped)

If your snowmobile has a tether switch, remove the tether from the switch to make sure the engine stops immediately.

Lighting

Check the headlight (high and low beam), taillight and brake light. Make sure all lights work properly before operating.

Mirrors (if equipped)

Adjust the mirrors so they can be used to their full advantage.

Operating Area

Before driving away, check your surroundings. Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile.

OPERATION

Ignition Switch

The ignition switch has three positions.

OFF Vehicle / IDD power off RUN Vehicle / IDD power on START Activates starter motor (if equipped)

If equipped with electric start, turn the key to START to crank the engine. When the key is released, it automatically returns to the RUN position.

Snowmobiles equipped with electric start and/or IDD are equipped with a battery. If the key remains in the RUN position after using the engine stop switch to stop the engine, the IDD remains active. The IDD screen will turn off after several minutes of inactivity, but the IDD will continue to draw a small amount of current from the battery until the key is turned off. This feature is useful for accessing the IDD without starting the engine, but turn the key off when the IDD is not in use.

The IDD is not dependent on the battery while the engine is running, but the battery supplies a constant power source when the engine is turned off or when the engine is transitioning between forward and reverse operation. If the battery is not installed, the IDD reboots when the engine is started and when electronic reverse (PERC) is used.

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 81 for more information about the engine stop switch and throttle release switch.

SYSTEM WHAT IT DOES

Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Auxiliary Engine Stop Switch Interrupts ignition circuit Throttle Release Switch Enables Engine Control Unit (ECU)

software RPM limit

Tether Switch (Option) Interrupts ignition circuit

OPERATION

Starting the Engine

NOTICE: Engaging the starter when the engine is running WILL result in serious

1. Turn the key to the RUN position.

2. Pull the auxiliary engine stop switch up to the RUN position.

3. If equipped with electric start, turn the key to START to crank the

4. If not equipped with electric start, grasp the starter handle and pull

TIP:Don't pull the starter rope to the fully extended position and don't allow it to

5. If the engine does not start after several attempts, slightly depress

CAUTION! To avoid injury and/or engine damage, do not operate the electric starter or pull-rope starter while the engine is running.

NOTICE: Operating the vehicle immediately after cold starting could cause

Restarting an Engine

If the rider stops the engine by pushing the engine stop switch down, restart the engine using the normal starting procedure. If the engine fails to start using the normal procedure:

1. Push the engine stop switch down to the OFF position.

2. Turn the key to the OFF position.

3. With both switches OFF, squeeze and hold the throttle in the wide

4. Crank the engine several times to draw fresh air through the engine.

5. Release the throttle.

6. Restart the engine using the normal starting procedure.

engine damage, especially if the snowmobile is in reverse. Never engage the starter when the engine is running.

engine. Release the key to the RUN position when the engine starts.

slowly until the recoil engages; then pull abruptly to crank the engine.

snap back into the housing. Damage may result.

the throttle (no more than 1/4 inch (6 mm) open) while cranking the engine. When the engine starts, immediately release the throttle.

engine damage. Allow the engine to warm up for several minutes before operating the vehicle. If cold drive-away is attempted, the engine RPM may stumble slightly to protect the engine.

open position.

OPERATION

Break-In Period

Engine Break-In

Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine.

Premix the first tank of fuel and fill the oil reservoir as outlined below. Oil added to the fuel and oil injection systems will provide the necessary engine lubrication.

Oil Recommendations

First Tank of Fuel: POLARIS VES 2-Cycle Oil After Break-in: POLARIS VES 2-Cycle Oil

See page 137 for the part numbers of POLARIS products. Never mix brands of oil. Serious chemical reactions can cause injection

system blockage, resulting in serious engine damage. Oils may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All POLARIS oils are compatible with each other.

Initial Fuel Premix

Always premix fuel in 5-gallon (19-liter) increments in a separate fuel container. Never add oil directly to the fuel tank.

Fuel VES 2-Cycle Oil Ratio

Each 5 gal. (19 l) 16 oz. (473 ml) 40:1

OPERATION

Break-In Period

Engine Break-In

Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Vary the throttle openings and vehicle speeds to reduce friction on all closefitting machined parts, allowing them to break in slowly without damage.

NOTICE: Use of any lubricants other than those recommended by POLARIS

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

Oil Injection System

Always check and fill the oil bottle when refueling. See page 80.

NOTICE: Serious engine damage can occur without the proper lubrication.

Drive Belt Break-In

The break-in period for a new drive belt is 30 miles (48 km). During this time, vary the throttle position under 50% and limit full throttle use.

may cause serious engine damage. We recommend the use of POLARIS lubricants for your vehicle.

Check the oil bottle level often during the first tank of fuel. If the oil level doesn't go down, contact your dealer immediately.

Always take time to warm up the belt and driveline prior to operating the snowmobile. Free the track and skis from the ground before engaging throttle.

OPERATION

Track Warm-Up

WARNING! A loose track or flying debris could cause serious injury or death.

Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear support.

WARNING! Use of traction products such as studs will increase the possibility of track damage and/or failure. This could cause loss of control, resulting in serious injury or death. Always inspect for track damage before operating the snowmobile.

Follow these steps to ensure proper warm-up of the engine, drive train and track.

1. Never rotate a dry track. For best track performance, always lubricate the track with water or snow before rotating the track.

2. Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper. The track should be about 4 inches (10 cm) off the ground.

3. Start the engine and allow it to warm up two to three minutes.

4. Depress the throttle abruptly and allow the track to rotate several revolutions.

TIP:It will take longer to warm up the track sufficiently during colder outdoor

temperatures.

5. Release the throttle, apply the brakes, shut off the engine and lower the snowmobile to the ground.

6. Grasp the skis by their front loops and move them from side to side to loosen snow and ice.

Slide Rail and Track Cooling

NOTICE: 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. Avoid operating on ice, hard-packed surfaces or roads.

OPERATION

WARNING

Fuel

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel outdoors or in a well-ventilated area.

• Always turn off the engine before refueling.

• Do not overfill the tank. Do not fill the tank neck.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

• Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time.

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

OPERATION

Fuel Recommendation

For peak performance, POLARIS recommends the use of 91 octane fuel or higher. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol. Never use E85 fuel in your snowmobile.

NOTICE: Operating with obstructed fuel systems will result in serious engine

Fuel System Deicers

If you use non-ethanol fuel (sometimes labeled “non-oxygenated”), POLARIS recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline to prevent damage resulting from fuel system icing. Never use deicers or additives containing methanol. POLARIS recommends the use of Carbon Clean. See page 137 for the part numbers of POLARIS products.

If you use fuel with up to 10% ethanol (sometimes labeled “oxygenated”) do not add deicers or additives that contain any form of alcohol.

damage. Perform maintenance as recommended. Prolonged exposure to petroleum based products may damage paint.

Always protect painted surfaces when handling fuel.

OPERATION

ADD Mark

Safe

Range

Oil

Low Oil Level

Always maintain the oil level between the “ADD” mark and the bottle neck. Do not fill the bottle neck. See page 75 for oil recommendations.

1. Immediately stop the

engine if the low oil indicator light comes on.

2. Open the left side panel.

See page 94.

3. View the oil level in the

oil bottle.

4. Add oil as needed before

operating.

NOTICE: Operating the

The oil bottle cap is vented to allow proper oil flow . See your POLARIS dealer for recommended replacement parts.

snowmobile without adequate engine lubrication can result in serious engine damage. Always check the oil level when refueling. Add oil as needed.

OPERATION

Step 4

Step 3

Auxiliary Engine Stop Switch

Push the auxiliary engine stop switch down to ground out the ignition and stop the engine quickly. Pull the switch up to the RUN position to allow restarting.

Throttle Release Switch

The throttle release switch is designed to stop the engine if all pressure is removed from the throttle lever and the throttle cable or throttle plates do not return to the normal closed position.

WARNING! Operating the snowmobile with a faulty throttle release switch can result in serious injury or death in the event of an accident. If the throttle release switch does not shut off the engine during a throttle system malfunction, immediately push down the auxiliary engine stop switch. Do not start the engine again until the malfunction has been corrected by your dealer.

Test the throttle release switch system daily before operation.

1. Sit on the seat.

2. Start the engine and allow

it to idle.

3. Press and hold the lever

pivot as shown.

4. While preventing the lever

from pivoting, slightly push the throttle lever as shown. A properly functioning switch must shut down the engine.

Stop Switch

OPERATION

Throttle Lever

WARNING! An improperly functioning throttle lever may cause erratic

snowmobile behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine.

If the engine stops abruptly when the throttle lever is released:

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and throttle body to determine

what caused the throttle release switch to activate.

3. Test the throttle lever by compressing and releasing it several times.

The lever and cable must return to the idle position quickly and completely.

4. If the throttle lever operates properly, turn the ignition switch on and

go through normal starting procedures.

5. If the engine doesn’t start, take the snowmobile to an authorized

POLARIS dealer for service.

Throttle Lever Freeplay Inspection

Throttle lever freeplay is the gap created between the throttle lever and throttle block, as you push the throttle lever, prior to the throttle cable opening the throttle body plates. Excessive freeplay in the throttle cable may cause the throttle release switch to activate, potentially stalling the engine or preventing the engine from starting.

To inspect throttle lever freeplay, follow these steps:

1. Stop the engine.

2. Slightly push the throttle lever

until you feel the cable tension increase (throttle plates opening).

3. Insert the blade of a feeler

gauge between the throttle lever and throttle block. The gap must be .009-.029 in. (0.25-0.76 mm).

4. Adjust freeplay if the gap does not meet specification. See page 83.

Gap

.009-.029 in.

(0.25-0.76 mm)

OPERATION

Throttle Lever

Throttle Lever Freeplay Adjustment

Adjust throttle lever freeplay using the in-line throttle cable adjuster.

Lock

Nut

1. Locate the in-line adjuster on the throttle cable.

2. Loosen the lock nut.

3. Rotate the adjuster clockwise to DECREASE freeplay. Rotate the

adjuster counter-clockwise to INCREASE freeplay.

4. When freeplay is adjusted to .009-.029 in. (0.25-0.76 mm), tighten

the lock nut against the adjuster.

5. Start the engine and allow it to idle.

6. Turn the handlebar to the full left and full right positions. Verify that

engine RPM does not increase as the handlebar is turned. If engine RPM increases, the throttle lever freeplay is too tight and must be readjusted.

WARNING! Do not operate the snowmobile if throttle cable freeplay is to o tight.

In-Line

Adjuster

OPERATION

WARNING

POLARIS Electronic Reverse Control (PERC)

Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase if shifting is attempted when the engine is operating above idle speed.

• Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle.

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

Electronic reverse will activate only if the engine RPM is below 4000.

NOTICE: Engaging the starter when the engine is running WILL result in serious

engine damage, especially if the snowmobile is in reverse. Never engage the starter when the engine is running.

OPERATION

POLARIS Electronic Reverse (PERC)

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Make sure the area behind your vehicle is clear.

3. Push the yellow reverse button on the left-hand control for one

second, then release. The engine will automatically reduce RPM and start a reverse rotation. A flashing reverse light on the instrument panel will indicate that the snowmobile is in reverse.

4. Apply the throttle slowly to make sure the snowmobile is in

reverse.The maximum engine RPM will be 6000 when in reverse.

TIP:If the engine stops running, the snowmobile will be in forward gear when it's

restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

NOTICE: Engaging the starter when the engine is running WILL result in serious

2. Push the yellow reverse button for one second and release. The

3. Apply the throttle slowly to make sure the snowmobile is in

engine damage, especially if the snowmobile is in reverse. Never engage the starter when the engine is running.

engine will slow and begin to rotate forward. The light on the instrument panel will shut off.

forward.

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 inches (10 cm) off the ground.

Remove the key and cover the snowmobile.

Towing

For your safety, do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions.

WARNING! Objects towed with a rope have no braking power and can easily collide with 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 object and the tow hitch on the snowmobile should be used. If passengers are to be towed on a toboggan or sled, make sure the pole is at least four feet (1.2 meters) long to prevent any possibility of contact between the snowmobile's track and a person riding in the towed object.

WARNING! Braking distances increase when towing loads. Slow down to maintain control of the snowmobile.

If the snowmobile becomes inoperable and must be towed, and if it isn't possible to use a rigid tow bar, attach the tow rope to the ski spindles (not to the ski loops) to prevent damage to the steering components. Remove the drive belt before towing, and have someone ride on the towed snowmobile to operate the brake and steering when necessary.

NOTICE: Towing a disabled snowmobile with the drive belt in place can result in

serious damage to the engine and drive system. Always remove the drive belt from a disabled snowmobile before towing.

MAINTENANCE

Emission Control Information

Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile.

Emission Control Label

Your snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory-installed emissions information hangtag. These items are required by U.S. Environmental Protection Agency regulations. The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover. The ECI label should not be removed, even after you purchase the snowmobile. You may remove the factory-installed emissions information hangtag, which is intended solely for your use in making a purchasing decision.

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 (R+M)/2. If your snowmobile is equipped with a check engine light and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups.

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty , and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed. POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary.

Non-ionizing Radiation

This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

MAINTENANCE

POLARIS Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 171.

The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (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 checks at 1000 mile (1600 km) intervals.

All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, become the responsibility of the registered owner. If, during the course of the warranty period, part

failures occur as a result of owner neglect in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner.

Personal safety is critical when attempting to service or make adjustments to your snowmobile. If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfortable performing these tasks yourself, contact an authorized POLARIS dealer for service.

NOTICE: Hot components can cause damage to plastic. Always make sure the

exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection.

MAINTENANCE

Periodic Maintenance Interval Table

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 genuine POLARIS parts, available from your POLARIS dealer.

Item See

Clutch Alignment Offset (without belt)

Drive Belt Condition 115 IIII Clutches 114 CCC Belt Tension -- II II Clutch Sheaves 114 IIII

Engine Mounts -- IIII Recoil Rope -- II II VES System

(600 Engine Only) Coolant Level 105 IIRI Coolant Hose -- II II Coolant Circulation -- II I Coolant Leaks -- IIII Spark Plugs 104 IIRI Exhaust Pipe 108 II Exhaust Retaining

Springs

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate

Page

108 IIII

150 mi.

(240 km)

114 III

ENGINE/COOLING

-- C

500 mi.

(800 km)

CLUTCH

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Hose Routing -- IIII Hose Condition -- II II Fluid Leaks -- IIII Brake Pads 110 IIII Brake Disc -- IIII Parking Brakes 70 IIII Brake System 69

Brake Fluid 111 I

Throttle Lever 82 II I II Fuel Lines 101 IIII Oil Lines III Air Box -- III II

Auxiliary Shut-Off Switch

Throttle Release Switch 81 II I II Ignition Switch -- III I I Taillight 72 II I II Brake Light 72 III I I Headlight 72 III I I

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate

Page

150 mi.

(240 km)

110

FUEL MANAGEMENT

ELECTRICAL

72 II I II

(800 km)

BRAKES

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Ski Toe Alignment -- III Suspension Mounting

Bolts Bolt Torques II I Steering Fasteners -- III IC Rear Suspension

Fasteners Suspension Shock Oil -- R Rear Shock Threads 98 L Skags (Wear Bars) 125 III I I Ski Saddle/Spindle Bolts -- III I I Drive Chain Tension 109 III II Hood and Side Panel

Fasteners Rear Wheel Idler Bolts 121 II I II Idler Bolt Jam Nut 121 III I I Handlebar Centering -- I Tether Switch and Strap 72 III I I Track Tension 120 II I I I Track Alignment 122 III I I Front Limiter Strap -- II I I I Rail Slide Condition 128 I Chaincase Oil 98 IRI R I

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate

Page

150 mi.

(240 km)

-- II I I I

94 II I II

(800 km)

CHASSIS

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Diagnostic Display Code Definitions

Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground:

control unit and the item listed in the chart.

The wire is shorted to ground between the electronic

Shorted Load:

The wires leading to the item listed in the chart are

shorted together, or the item has shorted internally.

Short-to-Battery:

The wire leading from the item listed in the chart to

the electronic control unit is shorted to a wire at battery voltage.

Diagnostic Codes

Component Condition SPN FMI

Throttle Position Sensor

Vehicle Speed Sensor Data Erratic, Intermittent or Missing 84 2 Intake Air Temperature Sensor Voltage Too High 105 3

Barometric Pressure Sensor

Engine Temperature Sensor

Alternator Power Supply Potential (DC Chassis Voltage)

Exhaust Temperature Sensor Voltage Too High 173 3

ECU Memory Checksum/CRC Error 628 13 Injector 1 (MAG Driver Circuit Open/Grounded 651 5

Injector 2 (PTO) Driver Circuit Open/Grounded 652 5

Knock Sensor 1 Voltage Too Low 731 4 Ignition Coil Primary Driver 1

(MAG) Fuel Pump Driver Circuit Driver Circuit Open/Grounded 1347 5

Voltage Too High 51 3 Voltage Too Low 4 Abnormal Rate of Change 10

Voltage Too Low 4 Voltage Too High 108 3 Voltage Too Low 4 Voltage Too High 110 3 Voltage Too Low 4 Temperature Too High 16 Engine Overheat Shutdown 0 Temperature Above Normal Range 15 Voltage Too High 167 3 Voltage Too Low 4

Voltage Too Low 4

Driver Circuit Short to B+ 3

Driver Circuit Open/Grounded 1268 5

MAINTENANCE

Diagnostic Display Code Definitions

Diagnostic Codes

Component Condition SPN FMI

Knock Level Cylinder 1 (MAG) Maximum Detonation Correction

Knock Level Cylinder 2 (PTO) Maximum Detonation Correction

Sensor Supply Voltage 1 (TPS/TMAP Sensor Power)

Sensor Supply Voltage 2 (Ground Speed Sensor)

ECU Output Supply Voltage 2 (Injection Supply PWR)

Throttle Release Signal Voltage Too High 520194 3

Chassis Relay Driver Circuit Open/Grounded 520208 5

Exhaust Valve Solenoid (600 Only)

EV Actuator Driver (Controller) (800 H.O. Only)

Electronic Oil Pump Driver Circuit Open / Grounded 3589 4

Oil Pump or Fuel Injector Settings not Programmed

Limit Reached Knock Above Critical Level 16

Limit Reached Knock Above Critical Level 16 Voltage Too Low 3509 4

Voltage Too Low 3510 4 Voltage Too High 3598 3

Voltage Too Low 4

Voltage Too Low 4 Throttle Stuck 7

Driver Circuit Short to B+ 3 Driver Circuit Grounded 520215 5 Driver Circuit Short to B+ 3 Voltage Too High 520324 3 Voltage Too Low 4 Learn Failure 13 Hardware Failure 12 Commanded Pos. Not Achieved 7 PWM Set Missing 2 MAX Temperature Exceeded 520334 31 Signal Out of Range - Valve Open 520325 31 Signal Out of Range - Valve Mid 520326 31 Signal Out of Range - Valve Closed 520327 31 Short to Battery Voltage 520335 3 Short to Ground 4 Abnormal Transition 10

Driver Circuit Grounded 5 Out of Calibration 520241 13

1352 0

1353 0

MAINTENANCE

Strap

1/4-Turn

Fasteners

Opening

Removing

Hood and Side Panels

The hood and side panels protect the operator from moving parts. Never operate a snowmobile with the side panels open or removed. Always ensure that the hood and side panels are installed and securely latched before starting the engine.

Side Panels (Opening/Removing)

To open a side panel, rotate the two 1/4-turn fasteners at the upper edges of the side panel. Release the strap at the lower edge of the side panel.

T o remove a side panel, open the side panel, then pull the panel outward to release the tabs at the lower edge of the panel. Lift the side panel away from the snowmobile.

Hood Removal and Installation

1/4-Turn

Fastener

1. Remove the side panels.

2. Rotate the 1/4-turn fasteners

at the upper corners of the hood.

3. Disconnect the wire harness

leading to the console electronics.

4. Remove the hood assembly.

5. To reinstall the hood, slide

the nose clips into the nosepan.

6. Position the hood and align

the 1/4-turn fasteners at the back of the hood. Secure the fasteners.

7. Reconnect the wire harness.

8. Reinstall the side panels.

MAINTENANCE

Wire Harness

MAINTENANCE

L-Wrench

Step 3

Tools

An L-wrench and a tool kit (containing a spare belt, spark plug wrench and provisions for two spare spark plugs) are provided with the snowmobile. Open the left side panel to access the tools.

The L-wrench is used to open and close the driven clutch when working with the drive belt. The L-wrench, when properly engaged in the bracket, secures the fender to the console. To retrieve the Lwrench, rotate it counterclockwise and slide it upward from the bracket. When it’s not in use, return the L-wrench to the bracket and rotate it clockwise.

The tool kit is stored in a container attached to the left tube of the front bumper. Use the following procedure to remove the spare belt container from the snowmobile.

1. Rotate the spark plug

wrench counter-clockwise to release it from the bracket.

2. Pull the wrench upward to

remove it.

NOTE: The wrench secures the

container to the bumper.

3. Tilt the tool kit container

until the bracket detaches from the bumper tube.

Spark Plug Wrench

MAINTENANCE

Front Rear

Step 5

Step 6

Tools

4. Pull the container out of the compartment.

5. When reinstalling the drive belt into the container, fold the belt as

shown. Verify that the belt loop at the rear of the container is positioned slightly higher than the front loop.

Step 4

6. Slide the container into the

engine compartment at an angle.

7. Position the container

bracket onto the bumper tube and rotate it downward.

8. Reinstall the spark plug

wrench into the bracket and through the hole in the bumper tube.

9. Rotate the spark plug

wrench clockwise until it locks into place.

MAINTENANCE

Rear Shock Body

Lubricate rear shock body threads seasonally with a low-temperature synthetic grease.

Driveshaft Bearing

This model has sealed bearings that require no additional lubrication.

Chaincase Oil

Check and change the chaincase oil at the intervals outlined in the Periodic Maintenance Table beginning on page 88. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of Synthetic Chaincase Lubricant. See page 137 for the part numbers of POLARIS products.

Oil Level Check

1. Position the snowmobile on

a level surface.

2. Remove the fill plug.

3. Using a funnel, slowly add

the recommended oil until the fluid begins to overflow.

4. Clean the area with a clean,

dry shop towel.

5. Reinstall the fill plug.

Torque: 6-10 ft-lbs (8-13 Nm)

Fill Plug

Threads

Polaris 2015 600 / 800 SWITCHBACK, 2015 600 / 800 RUCH user guide

Specifications and Main Features

Frequently Asked Questions

User Manual