Polaris 550 Indy (2022) Owner's Manual

Download

2022

For Maintenance and Safety

OWNER’S MANUAL

550 Indy 550 Indy LXT 550 Indy Adventure

550 Voyageur Indy Evo RMK Evo

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

Operating, servicing, and maintaining a passenger vehicle or off-road

vehicle can expose you to chemicals including engine exhaust, carbon

monoxide, phthalates, and lead, which are known to the State of California

to cause cancer and birth defects or other reproductive harm. To minimize

exposure, avoid breathing exhaust, do not idle the engine except as

necessary, service your vehicle in a well-ventilated area and wear gloves

or wash your hands frequently when servicing your vehicle.

For more information go to www.P65Warnings.ca.gov/passenger-vehicle.

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

Code® with your smartphone.

2022 Owner’s Manual

550 INDY

550 INDY LXT

550 INDY ADVENTURE

550 VOYAGEUR

INDY EVO

RMK EVO

Unless noted, trademarks are the property of Polaris Industries Inc.

Loctite® is a registered trademark of Henkel Corporation. QR Codes® is a registered trademark of DENSO WAVE INCORPORATED. BatteryMINDer® is a registered trademark of VDC Electronics Inc. NGK® is a registered trademark of NGK Spark Plug Co., Ltd. NYOGEL® is a registered trademark of Nye Lubricants, Inc. MIKUNI® is a registered Trademark of MIKUNI CORPORATION. KLIM® is a registered trademark of Teton Outfitters, L.L.C. FOX® is a registered trademark of Fox Factory Inc. ORTOVOX® is a registered trademark of Ortovox Sportartikel Gmbh. SAE® is a registered trademark of Society of Automotive Engineers, Inc. Hayes® is a registered trademark of Hayes Bicycle Group, Inc. INVANCE® is a registered trademark of CVTECH-IBC INC.

Copyright 2020 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.

9939920 Rev 01

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. 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 can be performed by a factory certified Master Service Dealer (MSD) technician.

Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Your POLARIS dealership can perform all of your service needs during and after the warranty period.

For the most up-to-date owner’s manual visit https://www. polaris. com/en-us/ owners-manuals.

SAFETY SYMBOLS AND SIGNAL WORDS

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.

DANGER

DANGER indicates a hazardous situation which, if not avoided, WILL result in

death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, COULD result

in death or serious injury.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, COULD result

in minor to moderate injury.

NOTICE

NOTICE provides key information by clarifying instructions.

IMPORTANT

IMPORTANT provides key reminders during disassembly, assembly, and

inspection of components.

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.

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . 7

Safety . . . . . . . . . . . . . . . . . . . . . . 11

Features . . . . . . . . . . . . . . . . . . . . . 25

Gauge . . . . . . . . . . . . . . . . . . . . . 29

The Perfect Fit . . . . . . . . . . . . . . . . . . 33

Pre-Ride Inspections . . . . . . . . . . . . . . . 49

Operation . . . . . . . . . . . . . . . . . . . . 55

Maintenance . . . . . . . . . . . . . . . . . . 67

Specifications . . . . . . . . . . . . . . . . . . 113

POLARIS Products . . . . . . . . . . . . . . . . 135

Troubleshooting . . . . . . . . . . . . . . . . . 137

Warranty . . . . . . . . . . . . . . . . . . . . 143

Maintenance Log . . . . . . . . . . . . . . . . 153

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 at specific mileage intervals. This service can be performed by your authorized POLARIS dealer.

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 nonsnowmobilers, 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.

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

Tunnel VIN

Certification Label

VEHICLE MODEL NUMBER:

TUNNEL VIN (RIGHT SIDE OF TUNNEL):

ENGINE SERIAL NUMBER (ON RECOIL HOUSING):

KEY NUMBER:

INTRODUCTION

ENGINE SERIAL NUMBER

The engine serial numberqis located on the identification label on top of the engine recoil housing.

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

Follow the recommended maintenance program beginning on page 68 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected at specific mileage intervals. Your dealer can perform this service.

WARNING

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.

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.

SAFETY

STAY CLEAR OF ENGINE

Never attempt adjustments with the engine running. Turn off the ignition, open the side panels or hood, make the adjustment, secure shields and guards, secure the side panels and hood, and then restart the engine to check its operation.

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.

RIDING APPAREL

HELMET

Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.

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.

SAFETY

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.

CLOTHING

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.

Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See page 20.

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:

SAFETY

• Spare Drive Belt

• Extra Set of Spark Plugs

• Tow Rope

• Extra Oil

• Fuel Deicer

• Winter Survival Kit

• Trail Map

• First Aid Kit

• Tool Kit

RIDER CAPACITY

Some POLARIS snowmobiles are designed for a single rider only, while some are designed for up to two riders. A safety label on the vehicle indicates whether the vehicle is designed for a single rider or for two riders.

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.

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.

SAFETY

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.

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.

You 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.

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.

SAFETY

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 hard-packed

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 the slide

rail, track and/or engine.

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.

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.

HIDDEN OBSTRUCTIONS

Always be aware of surroundings and terrain when riding your snowmobile. Hazardous obstructions may be hidden beneath the snow. Reduce speed and use extra caution whenever riding off established trails. Striking a hidden obstacle could cause loss of control of your vehicle and lead to severe injury or death. Remain on established trails whenever possible to reduce exposure to hazards.

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 crossing 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

DRIVE BELT

Do not operate the engine with the drive belt removed.

Any servicing that requires operation without a belt can be performed by your dealer.

WARNING

Operation of the engine with the belt removed may result in injury or damage to

the engine.

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 removed.

CLUTCHES

Do not attempt to service the clutches.

All clutch service can 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.

On 2-up machines, always operate with respect for a passenger.

SAFETY

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 based on rider weight and foot position on running boards.

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

WINDCHILL/TEMPERATURE CHARTS

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

WINDCHILL CHART (°F)

Wind

Speed

in MPH

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

5 36 31 25 19 13 7 1 -5 -11 -16 -22 -28 -34 -40 -46 -52

10 34 27 21 15 9 3 -4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72 15 32 25 19 13 6 0 -7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77 20 30 24 17 11 4 -2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81 25 29 23 16 9 3 -4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84 30 28 22 15 8 1 -5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87 35 28 21 14 7 0 -7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89 40 27 20 13 6 -1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91 45 26 19 12 5 -2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93 50 26 19 12 4 -3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95 55 25 18 11 4 -3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97 60 25 17 10 3 -4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98

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

Frostbite in >> 30 min. 10 min. 5 min.

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

-57 -63

WINDCHILL CHART (°C)

Wind

Speed

in Km/h

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

8 3 0 -4 -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50

16 2 -2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 24 1 -3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 32 0 -4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67 40 -1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69 48 -1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70 56 -2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72 64 -2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73 72 -2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74 80 -3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75 88 -3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76 96 -3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

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

Frostbite in >> 30 min. 10 min. 5 min.

Actual Thermometer Reading (°C)

Equivalent Temperature (°C)

-53 -57

SAFETY

SAFETY LABELS AND LOCATIONS

Warning labels are placed on the snowmobile for your protection. Read and follow the instructions of the labels and 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.

CLUTCH WARNING/BELT REMOVAL

This warning label is found on the clutch cover. Part number: 7176327.

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 the tool kit into the open threaded hole in the driven

clutch.

3. Turn the L-wrench clockwise to open the sheaves and replace the belt.

Return the L-wrench to the tool kit.

SEE OWNER’S MANUAL FOR SHEAVE WIDTH ADJUSTMENT PROCEDURE.

NO PASSENGER WARNING

The No Passenger warning label is located near the steering post. Part number:

7172575.

WARNING

This vehicle is designed for operator only. “NO PASSENGER”

PASSENGER WARNING

This label is applicable to passenger models only. If equipped, the label is located near the steering post. Part number: 7173385.

SAFETY

WARNING

This vehicle is designed for operator and “ONE” passenger only.

PASSENGER WEIGHT WARNING

The passenger weight warning label is located on the passenger seat, if equipped. Part number: 7179883.

WARNING

Max Passenger Weight 150 (68 kg) See Owner’s Manual for Required Suspension Adjustment.

OPERATION WARNING

The Operation Warning label

Part Numbers: 7176779 (English), 7176780 (French Canadian).

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.

is located on either side of the operator seat.

• 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.

SAFETY

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

• Before starting the engine, check throttle, brake, and steering for proper operation. Make sure hood is latched. Be seated and in position to control the vehicle.

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

REPORTING SAFETY DEFECTS (CANADA)

To report a safety defect to Transport Canada, you may either fill out an online defect complaint form at their website (English: http://www/tc/gc/ca/recalls, French: http://www.tc.gc.ca/rappels) or contact their Defect Investigations and Recalls Division by calling toll-free 1-800-333-0510 (Canada) or 819-994-3328 (Ottawa-Gatineau area / International).

FEATURES

COMPONENT LOCATIONS

NOTICE

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

Skis

Nosepan

Front Bumper

Hood

Headlight

Windshield (accessory)

Handlebar

Operator Seat

Taillight

Rear Bumper

Snow Flap

Upper Control Arm

Lower Control Arm

Spindle

IFS Shock

Side Panel

Torsion Spring

Rear Track Shock

Front Track Shock

Rail

FEATURES

ADDITIONAL COMPONENT LOCATIONS

Instrument Cluster

Ignition Switch

Engine Stop Switch

Recoil Starter Handle

Brake Lever

Parking Brake Lock

Handlebar Grip Warmer Switch

Thumb-warmer Switch

Electronic Reverse Button

Headlight Dimmer Switch

Tool Kit/Storage Bag

ADJUSTABLE HEADLIGHTS

FEATURES

Move the headlight adjuster left to adjust the headlight beam upward. Move the adjuster to the right to adjust the beam downward.

to the

CARGO STORAGE (IF EQUIPPED)

155 MODELS

The maximum weight capacity for the cargo area is 50 lbs. (23 kg). When combined with hitch tongue weight, the maximum weight capacity is 65 lbs. (29.5 kg). Always secure cargo before operating. Do not exceed the weight limit.

144 MODELS

The maximum weight capacity for the cargo area is 30 lbs. (14 kg). Always secure cargo before operating. Do not exceed the weight limit.

TOOL KIT

The tool kit is located in the toe of the left footwell.

NOTICE

Spare belt and spark plugs are not provided with the snowmobile.

1. Wrench, Spark Plug

2. Wrench, Open End, 9/16 x 1/2

3. Belt Removal Tool

4. Screwdriver

ACCESSORIES

POLARIS offers a wide range of accessories for your snowmobile to help make each ride more enjoyable.

Use only POLARIS parts and accessories on your POLARIS snowmobile. Use of unapproved parts and accessories may result in:

FEATURES

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others

This applies to, but is not limited to the following areas: brakes, clutches, fuel systems, and exhaust systems. Exhaust systems are critical safety areas that must use approved POLARIS parts. Please see your POLARIS dealer for service.

GAUGE

STANDARD INSTRUMENT CLUSTER

GAUGE

Low Oil

Low Battery Voltage

NOTICE

Certain products will damage 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.

High Beam

Parking Brake

Reverse

GAUGE

INDICATOR LAMPS

INDICATOR CONDITION

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.

The low battery voltage indicator illuminates when the battery voltage is low.

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

The parking brake Indicator illuminates when the parking brake is engaged. It will also illuminate when the service brake is in use.

The reverse indicator flashes when the vehicle is in reverse. Slow flash for low elevation. Fast flash for high elevation

(above 6000 ft.). To change from low to high elevation. hold the reverse button for 5 seconds.

GAUGE

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.

Information Display Area - This area displays either engine speed or vehicle

speed (whichever is not displayed in the speed display), and maximum vehicle speed.

Speed Display - The speed display area displays either vehicle speed or

engine speed.

Odometer/Engine Hour Display - This area displays the odometer, Trip A,

Trip B and engine hours.

GAUGE

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 release the center button.

INFORMATION DISPLAY AREA

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

ODOMETER/ENGINE HOUR DISPLAY AREA

This area displays the odometer, Trip 1 meter, Trip 2 meter, CLOCK, 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 CLOCK displays the time, and the engine hour meter displays the total hours the engine has been in operation since manufacture.

To change the display, press and release the SET button or SET switch until the desired item is displayed.

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

THE PERFECT FIT

FRONT SUSPENSION ADJUSTMENTS

Factory settings, combined with user adjustments to the rear shock spring, should be all that’s necessary to provide the best riding experience for most riders. If all rear shock spring adjustments have been exhausted and rider weight is at the very high or very low weight range for the stock spring, additional adjustments are possible to the IFS,

Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. The snowmobile should be methodically tested, one change at a time, under the same conditions (trail and snow conditions, vehicle speed, riding position, etc.) after each adjustment until the best ride is achieved.

Break in the suspension for about 150 miles (240 km) before making adjustments to the front suspension.

IFS COMPONENTS

Skis

Front Shocks and Springs

Rod Ends

A-arms

THE PERFECT FIT

IFS ADJUSTMENT OPTIONS

• Front shock spring preload

• Optional springs

IFS SHOCK SPRING PRELOAD (IF EQUIPPED)

Increasing spring preload increases ski-to-ground pressure. Decreasing spring preload decreases ski-to-ground pressure. When adjusting, ensure the springs on both sides of the machine are set to the same length. To adjust shock spring preload, grasp the spring retainer and rotate it. Some models are not equipped with IFS spring adjuster. Please see your POLARIS dealer for accessory options.

IMPORTANT

Before adjusting, elevate the front end of the

snowmobile so the skis are lifted off the

ground. All measurements are taken with no

pressure on the front suspension.

Factory Installed Spring Length

121 Models (Not Including EVO models)

155 Models 10.14 in (25.7 cm)

EVO and EVO RMK 7.94 in (20.2 cm)

10.40 in (26.4 cm)

Never exceed 1 in (2.54 cm) of preload beyond the factory settings. Overextending the spring preload may adversely affect the handling of the snowmobile and the performance of the suspension.

THE PERFECT FIT

When decreasing preload, ensure there are at least two full turns of preload holding the spring between the retainer on the top of the shock and the threaded spring preload adjuster nut on the shock body. Failure to do so could cause the retainer to fall off when the suspension is fully extended.

REAR SUSPENSION ADJUSTMENTS

Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action.

Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snowcross racing would provide a very stiff ride on the trail. A suspension set up for trail riding would bottom out harshly on a snowcross course.

Refer to the suspension setup label on your snowmobile, or your POLARIS dealer can provide the initial suspension setup information. Additional adjustments can be made after initial setup. Make adjustments to one area at a time so you can evaluate the change. For further assistance, your dealer can assist.

SUSPENSION PERFORMANCE TIPS

• Rider weight usually determines the position at which the spring preload should be set. However, this may vary with riding style. With a little experimentation, each rider can find a preferred set-up. These adjustments are easy to make, involve very little time or effort, and greatly affect the ride.

• In deep snow, a new rail slide will offer improved performance over a worn rail slide. It can also improve top speed.

• When riding on ice or hard-packed snow, adding a set of bogie wheels to the rail may enhance the snowmobile’s performance. Bogie wheel kits are available from your dealer.

• POLARIS offers track kits for improved flotation in deep snow. See your dealer for assistance.

TIP

Keep the suspension pivot points lubricated. This will reduce moisture and rust

build-up and ensure proper function of the suspension components. Grease

rear suspension pivots before adjusting the rear suspension.

TRACK TENSION

Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Refer to the track tension maintenance section of this manual.

THE PERFECT FIT

REAR TRACK SHOCK SPRING (144)

Measure the rear track shock spring length and adjust to the appropriate length based on rider weight. Include passenger weight (if applicable) and all riding gear, accessories and cargo weight in the calculation.

WARNING

Allow a passenger to ride only on models equipped with a passenger seat.

1. Securely elevate and support the rear of the snowmobile to remove the weight from the suspension.

2. Use a tape measure to measure the spring installed length between the two spring retainers.

3. Refer to the chart on the next page to determine the correct spring length for rider weight. If adjustment is needed, clear away any snow or ice trapped within the spring or threads.

4. Using a spanner wrench, rotate the spring to adjust length.

NOTICE

Never adjust a spring beyond the maximum adjustment length shown in the

chart. Adjusting beyond maximum adjustment will cause the spring to bottom

and result in damage to your rear suspension.

Adjust the rear track shock spring per the charts on below.

EVO RMK MODELS

REAR TRACK SHOCK SPRING (RTSS) SET-UP

(Standard Spring)

Measure spring length with suspension off the ground

Rider Weight(including all riders,

gear, cargo, & accessories

Shaded cells indicate factory settings.

< 160 lbs

< 73 kg

Model Installed Spring Length(rear

suspension off the ground)

EVO RMK 9.5 in. 24.1 cm

160-220 lbs

220-280 lbs.

73-100 kg

100-127 kg

*RMK EVO maximum adjustment is 8.5 in. (21.6 cm)

EVO RMK 9.12 in. 23.2 cm

EVO RMK 8.75 in. 22.2 cm

550 INDY MODELS

REAR TRACK SHOCK SPRING (RTSS) SET-UP

Measure spring length with suspension off the ground

THE PERFECT FIT

(Standard Spring)

Rider Weight (including all riders,

gear, cargo, & accessories

Shaded cells indicate factory settings.

< 160 lbs

160-220 lbs

220-280 lbs.

280-340 lbs.

< 73 kg

73-100 kg

100-127 kg

127-154 kg

Model Installed Spring Length (rear

suspension off the ground)

550 INDY

Adventure/

Voyageur/LXT

550 INDY 144

550 INDY

Adventure/

Voyageur/LXT

550 INDY 144 10.5" 26.7 cm

550 INDY

Adventure/

Voyageur/LXT

550 INDY 144 10.125" 25.7 cm

550 INDY

Adventure/

Voyageur/LXT

550 INDY 144 9.75"

11.125" 28.2 cm

10.75" 27.3 cm

10.5" 26.7 cm

10.125" 25.7 cm

24.7 cm

Maximum

Adjustment

Maximum

Adjustment

340-360 lbs.

154-163 kg

550 INDY

Adventure/

Voyageur/LXT

9.875"

Maximum

Adjustment

25 cm

Maximum

Adjustment

THE PERFECT FIT

INITIAL SPRING PRELOAD SETTING (SAG METHOD)

To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X.

Take the first measurement with no rider and with the rear suspension at full extension.

TIP

The rear bumper may need to be lifted upward slightly to fully extend the

suspension.

Next, have the rider drop down hard on the seat and bounce up and down several times, collapsing the rear suspension. With the rider seated, measure the distance between the ground and the rear bumper at the exact location used for measurement X. This is measurement Y.

To determine sag, commonly referred to as ride-in, subtract measurement Y from X (sag=X-Y). If the measured sag is incorrect, adjust the FRA position and/ or rear torsion spring preload.

SUSPENSION RECOMMENDED

SAG

INDY 121 3-4 inches (7.5-10

cm)

ADJUSTMENT SEE PAGE

Torsion Spring Preload

page 39

INDY 155 4 inches (10 cm) Torsion Spring

Preload

INDY EVO 1.5-2.5 inches (3.8-

6.3 cm)

Torsion Spring Preload

page 39

THE PERFECT FIT

TIP

This is only an initial setup, and final spring preload may vary based on rider

preference and riding conditions. Accessory springs with a higher load rating

are available for some models. Please see your dealer for availability.

TORSION SPRING PRELOAD (121)

To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more effort.

Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information.

Low Medium

High

TORSION SPRING PRELOAD (155)

To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information.

The following information is provided only as a guideline to be used for initial suspension set-up. Your set-up may vary based on your desired riding style.

Soft

(long end of cam to

front)

Medium

(short end of cam up)

Firm

(long end of cam up)

THE PERFECT FIT

LIMITER STRAP POSITION (SKI PRESSURE)

Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter strap strap to increase ski pressure. Loosen the strap to reduce ski pressure.

1. Remove the nuts and flat washers from the upper limiter strap.

2. Relocate the strap to the desired position.

3. Reinstall the nuts and washers. Tighten securely.

. Tighten the

THE PERFECT FIT

SUSPENSION COUPLING (121 MODELS ONLY)

On all POLARIS snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other. Rear suspension coupling links the movement of the front and rear torque arms to each other.

There are two types of rear suspension coupling.

FRONT TO REAR COUPLING AND THE FRONT REAR SCISSOR STOP (FRSS)

The front rear scissor stop (FRSS) couples the movement of the front torque arm with the rear torque arm and limits the amount of independence between the movement of the front torque arm and the rear torque arm.

When hitting a bump, the front torque arm starts to compress. The FRSS links the movement to the rear torque arm, causing it to compress and raise the rear suspension up as one, allowing the suspension to hit the bump only once and reducing kickback.

The factory setting is usually adequate for all riders and conditions.

REAR TO FRONT COUPLING AND THE REAR REAR SCISSOR STOP (RRSS)

The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm.

Adjusting the RRSS either allows more weight to transfer to the rear for more traction, or allows less weight to transfer to the rear, resulting in improved cornering performance. An adjustment dot is located on the RRSS. This dot is on the longest end of the scissor stop.

REAR REAR SCISSOR STOP (RRSS) - ATTRIBUTES

Moving the RRSS to a higher position will have the following effects on the suspension:

• Reduced weight transfer

• Improved chatter bump ride

• Improved cornering performance

• Increased load carrying capacity (2–up)

THE PERFECT FIT

WEIGHT TRANSFER DURING ACCELERATION

The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions.

To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position.

To increase weight transfer or ski lift during acceleration, rotate the RRSS to a lower position.

NOTICE

When adjusting for weight transfer, both the left and right rear rear scissor stop

adjuster blocks must be adjusted to the same position.

High

Medium

THE PERFECT FIT

Low

TIP

Your dealer can help you with initial setup and additional setup instructions to help you achieve your optimum ride. A scissor stop tool is also available from

your dealer.

Low

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 vehicle steering and control. See page 98.

If your snowmobile has carbide skags, it may be necessary to add track studs to maintain proper vehicle control. 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.

Inspect skags frequently. Worn skags may reduce steering and braking control on hard-packed snow and ice. Replace worn skags to maintain proper balance and vehicle control.

WARNING

Loss of control can result in serious personal injury or death. Proper balance of

traction products on the skis and track must be maintained to obtain proper

vehicle control on hard-packed snow or ice. See your dealer for assistance.

WEAR STRIPS

To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used.

Install the appropriate wear strip kit. See your dealer.

Wear strips are designed for a specific stud length. See your dealer’s studding chart for recommended traction accessories.

NOTICE

Whenever wear strips are relocated, be sure there’s adequate stud clearance

to the tunnel. Lack of clearance may result in damage to tunnel.

THE PERFECT FIT

HANDLEBAR COMPONENT FASTENER TORQUES

COMPONENT TORQUE

DO NOT OVER-TIGHTEN

IMPORTANT: Moving a handlebar component without first loosening its screws/ set screws may cut grooves into the handlebar, making it difficult to secure the component. Do not move a handlebar component without first loosening its mounting screws/set screws. Take care to avoid damaging hand warmer/brake switch wires when moving components.

Left Hand Control/Brake Master Cylinder 24 in-lbs (2.7 Nm)

Upper / Lower Handlebar Clamps 7 ft-lbs (9.5 Nm)

Throttle Lever Block Set Screw 35 in-lbs (4 Nm)

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

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

Hand Guard Mounts (if applicable) Hand-Tight

THE PERFECT FIT

LEFT HAND CONTROL ALIGNMENT

1. Loosen the four control block mounting screws.

CAUTION

Take care to avoid damaging hand warmer/brake switch wires when moving

components.

2. Move the control block to the desired position.

NOTICE

If the control is loose and was inadvertently moved without loosening the

screws, move the control block slightly to the left or right to relocate the pins.

3. Tighten the screws to specification in the sequence shown in the image. Do not over-torque.

TORQUE

Control Block Mounting Screws

24 in-lbs (2.7 N·m)

THROTTLE BLOCK ALIGNMENT

THE PERFECT FIT

CAUTION

Take care to avoid damaging hand warmer/brake switch wires when moving

components.

1. Slightly loosen the set screw

2. Move the control block to the desired position.

3. Tighten the screw to specification. Do not over-torque.

4. With the engine off, test throttle lever movement after tightening the screw. See page 63.

on the bottom of the housing.

TORQUE

Set Screw

35 in-lbs (4 N·m)

THE PERFECT FIT

HANDLEBAR ADJUSTMENTS

HANDLEBAR ANGLE

1. Securing the handlebar clamp bolts the four nuts (located on each bolt’s opposite end).

CAUTION

Take care to avoid damaging hand warmer/brake switch wires when moving

components.

2. Adjust the handlebar forward or rearward to the desired angle.

3. 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, adjust the left and right hand controls. See page 46.

4. Tighten the handlebar clamp nuts. Do not over-torque.

TORQUE

Handlebar Clamp Nuts

7 ft-lbs (9.5 N·m)

with an Allen wrench, loosen each of

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 page 88

Steering System page 53

Recoil Rope page 54

Chaincase Oil Level page 76

Engine Oil Level page 60

Parking Brake Lock/Brake Lever/Brake System

Auxiliary Shut-Off Switch (Engine Stop Switch)

Ignition Switch page 54

Headlight/Taillight/Brake Light page 54

Suspension Mounting Bolts page 50

Skags (Wear Bars) page 98

Ski Saddle and Spindle Bolts page 92

Hood and Side Panel Fasteners page 74

Throttle Lever/Safety Switch page 51

Rear Wheel Idler Bolts page 92

Tether Switch/Strap (if equipped) page 54

Track Alignment/Condition page 96

Rail Slide Condition page 100

page 52, page 51, page 85

page 54

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 SECTION

Check suspension mounting bolts for tightness.

Check rear idler wheel bolts for tightness.

Check rear idler adjusting bolt locknuts for tightness.

Check torque arm bolts for tightness.

Check carrier and bogie wheel bolts for tightness.

Check front torque arm limiter strap condition.

Check rail slide condition. page 100

Check track tension. page 35

page 35

Check lubrication on all rear suspension components.

Check ski runner/skag condition. page 98

Check ski spindle bolts for tightness.

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 malfunctioning 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 SAFETY SWITCH

Test the throttle safety switch system before the snowmobile is operated.

BRAKES

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

BRAKE LEVER TRAVEL

Squeeze the brake lever. It should move no closer to the handgrip than 0.5 inch (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. See page 87 or see your dealer for service.

PRE-RIDE INSPECTIONS

LEVER FEEL

If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See the Brake Fluid section for details.

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.

PARKING BRAKE LEVER LOCK

Use the 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.

Brake Lever

Parking Brake Lever Lock

Master Cylinder Reservoir/Cover

Fluid Level Indicator

LOCK ENGAGEMENT

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

NOTICE

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 on the gauge will light up if the parking brake lever lock is set while the engine is running. It will also be lit 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.

PRE-RIDE INSPECTIONS

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.

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.

SEAT LATCHES

If your snowmobile is equipped with a removable or tip-up seat, ensure that the seat latches are securely in place before every use of the snowmobile.

PRE-RIDE INSPECTIONS

HOOD AND SIDE PANEL FASTENERS

CAUTION

The hood and side panels of the snowmobile protect the operator from moving

parts. Never operate a snowmobile with the hood or side panels open or

removed. Always ensure that the hood and side panels are securely in place

before starting the engine.

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, your POLARIS dealer can provide a replacement.

START 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 page 51.

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 SWITCH

Make sure the engine stops when the ignition 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. Replace burned out lamps 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

STARTING THE ENGINE

FULL CHOKE

1/2 CHOKE

OFF

CAUTION

OPERATION

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

damage, especially if the transmission is in reverse. Never engage the starter

when the engine is running.

1. Turn the fuel valve on. See page 60.

2. Turn the key to the ON position

3. Pull the engine stop switch up to the RUN position.

4. If starting a cold engine, flip the choke toggle to FULL CHOKE. Do not use the choke if starting a warm engine. Do not depress the throttle until the engine starts.

CAUTION

To avoid injury and/or engine damage, do not operate the electric starter or

pull-rope starter while the engine is running.

NOTICE

Don’t pull the starter rope to the fully extended position and don’t allow it to

snap back into the housing. Damage may result.

5. If equipped with electric start, turn the key to START to crank the engine. Release the key to the ON position when the engine starts.

6. If not equipped with electric start, grasp starter handle and pull slowly until the recoil engages, then pull abruptly to crank the engine.

7. Repeat the cranking procedure as needed until the engine starts.

OPERATION

8. After the engine starts, flip the choke toggle to the OFF position. If the engine slows or wants to stop, use intermittent choking to the HALF CHOKE position.

9. Before turning the engine off, operate the choke intermittently to draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen.

EMERGENCY STOPPING

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 54 for more information about the engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES THROTTLE

CONDITION

Ignition Switch Interrupts ignition circuit All

Brake Slows jackshaft All

Choke Floods engine Half throttle or less

Engine Stop Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

Tether Switch (accessory)

Interrupts ignition circuit All

OPERATION

BREAK-IN PERIOD

ENGINE BREAK-IN

Polaris recommends the use of POLARIS Blue 2-Cycle Semi-Synthetic Oil for your snowmobile, including extreme arctic conditions with a sustained temperature at or below -40° F (-40° C).

NOTICE

Use of any lubricants other than those recommended by POLARIS may cause serious engine damage. We recommend the use of POLARIS lubricants, or an

equivalent product, for your vehicle.

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 bottle with the recommended oil. Oil added to the fuel and oil injection systems will provide the necessary engine lubrication.

INITIAL FUEL PREMIX

The first tank of fuel should contain a 40:1 ratio of fuel to oil premix. NEVER mix oil brands. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. Oils may 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.

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

POLARIS BLUE 2-CYCLE SEMI-

FUEL

Each 5 gal (19 L) 16 oz (473 mL) 40:1

SYNTHETIC OIL RATIO

FIRST THREE HOURS OF ENGINE USE

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 close-fitting machined parts, allowing them to break in slowly without damage.

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 during pre-ride inspection and refueling.

OPERATION

NOTICE

Serious engine damage can occur without the proper lubrication. Check the oil

bottle level often during the first tank of fuel. If the oil level doesn't go down,

contact your dealer or other certified technician immediately.

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.

New drive belts should be washed with warm, soapy water and allowed to air dry prior to use.

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.

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, ice growsers, etc. 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. 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.

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

3. 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.

OPERATION

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

5. 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.

FUEL

WARNING

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.

WARNING

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.

FUEL RECOMMENDATION

Your POLARIS engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There's a great deal of variability in the quality of the 87 octane gasoline available across the country, so we encourage the use of premium fuel when possible. Do not use fuel containing more than 10% ethanol (including E85).

OPERATION

NOTICE

Using fuels with a lower than recommended octane or operating with

obstructed fuel systems will result in serious and costly engine damage.

Always use the recommended fuels for your machine.

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 1-2 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.

IMPORTANT

If you use fuel with up to 10% ethanol (sometimes labeled “oxygenated”) do

not add deicers or additives that contain any form of alcohol. Adding deicer to

oxygenated fuels could result in severe engine damage.

FUEL VALVE

The fuel valve is located near the lower rear area of the oil bottle. Turn the fuel valve off whenever the snowmobile is stored, parked or transported.

Turn the fuel valve clockwise to OFF to shut off the fuel supply.

Turn the valve counter-clockwise to ON to turn the fuel supply on.

LOW OIL LEVEL

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

1. Immediately stop the engine if the low oil indicator light comes on.

2. Open the right side panel.

3. View the oil level in the oil bottle.

4. Add oil as needed before operating.

NOTICE

Operating the snowmobile without adequate engine lubrication can result in

serious engine damage. Always check the oil level when refueling. Add oil as

needed.

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

OPERATION

LOW OIL INDICATOR LIGHT

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 the Engine Break-in section for oil recommendations.

CARBURETION

NOTICE

Making non-recommended adjustments could result in vehicle or engine

damage as well as denial of warranty claims. Your Polaris dealer can assist

with any carburetor adjustments.

Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance.

A lean mixture may be caused by things like fuel line restrictions, foreign matter in the carburetor or clogged fuel filters. A rich mixture may be caused by snow build-up on the pre-filter in the air intake system. Either condition may be caused by improper carburetor adjustment.

JETTING GUIDELINES

Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense.

The carburetors are calibrated for an altitude of 0-2000 ft. (0-600 m) and ambient temperatures of -15° to +5° F (-26° to -15° C). Carburetors must be recalibrated if the snowmobile is operated outside this production temperature and/or altitude range. The main jet installed in production is not correct for all altitudes and/or temperatures. See page 82 for more information.

NOTICE

A main jet that’s too small will cause a lean operating condition and may cause

serious engine damage. Jet the carburetors carefully for elevation and

temperature according to the jetting charts.

TIP

It’s the owner’s responsibility to ensure that the correct jets are installed in the

machine for a geographical area. Be very careful when jetting down in warm

weather. As the weather turns colder it will be necessary to re-jet to prevent

engine damage. When selecting the proper main jet always use the lowest

elevation and temperature that is likely to be encountered.

OPERATION

ENGINE STOP SWITCH

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

THROTTLE SAFETY SWITCH

WARNING

Operating the snowmobile with a faulty throttle safety switch can result in

serious injury or death in the event of an accident. If the throttle safety switch

does not shut off the engine during a carburetor/throttle system malfunction,

immediately push down the engine stop switch. Do not start the engine again

until the malfunction has been corrected by your dealer.

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

Test the throttle safety switch system daily before operation.

1. Sit on the seat.

2. Start the engine and allow it to idle.

3. Hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration.

4. Apply a slight amount of throttle. A properly functioning switch must shut down the engine.

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 carburetor/throttle body to determine what caused the safety 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, your authorized POLARIS dealer can perform this service.

Excessive freeplay in the throttle cable may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the snowmobile to an authorized POLARIS dealer for service.

If an emergency exists and it's necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from the wire harness. When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the snowmobile with the throttle safety switch disconnected. Return the snowmobile to an authorized POLARIS dealer for service as soon as possible.

POLARIS ELECTRONIC REVERSE CONTROL (PERC)

WARNING

Improper reverse operation, even at low speeds, may cause loss of control,

resulting in serious injury or death. Damage will occur to the chaincase or

transmission 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.

OPERATION

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

CAUTION

Engaging the starter when the engine is running WILL result in serious engine damage, especially if the engine is in reverse. Never engage the starter when

the engine is running.

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 vehicle is 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.

CAUTION

Engaging the starter when the engine is running WILL result in serious engine damage, especially if the engine is in reverse. Never engage the starter when

the engine is running.

2. Push the yellow reverse button for one second and release. The engine will slow and begin to rotate forward. The light on the instrument panel will shut off.

3. Apply the throttle slowly to make sure the vehicle is in forward.

HIGH ALTITUDE SETTING

At altitudes above 6000 feet (1800 m), the engine will require a different ignition setting to improve the success of the reverse system. To set for a higher altitude, start the engine and hold the reverse button down until the light on the gauge flashes rapidly, then release the button.

OPERATION

To set the reverse for lower elevations, continue holding the button down until the reverse indicator light blinks slowly. Once set, it’s stored in memory until changed, whether the machine is running or not.

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. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions related service, however equivalent parts may be used for such service. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering with emission controls is prohibited by federal law.

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, or other qualified person, to perform any service that may be necessary.

NON-IONIZING RADIATION

This vehicle emits some electromagnetic energy. People with active or nonactive 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

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.

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 153.

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, your authorized POLARIS dealer can provide any needed service.

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.

I - INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF NECESSARY) C - CLEAN, R - REPLACE, L - LUBRICATE

FREQUENCY

ITEM

Drive Belt Condition (See page 88)

Clutches

Belt Tension

Clutch Sheaves

Engine Mounts

Engine Torque Stop (See page 88)

Recoil Rope

Cylinder Head Bolts

150 MI.

(240 KM)

CLUTCH

ENGINE/COOLING

500 MI.

(800 KM)

I I I I

C C C

I I I I

I I I

KM)

1000 MI. (1600

KM)

2000 MI. (3200

PRE- SEASON

Cylinder Base Nuts

Ignition Timing BTDC

Spark Plugs (See page 78)

Exhaust Pipe (See page 81)

Exhaust Retaining Springs (See page 81)

I I I

I I R I

I I

I I I

MAINTENANCE

I - INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF NECESSARY) C - CLEAN, R - REPLACE, L - LUBRICATE

FREQUENCY

ITEM

Hose Routing

Hose Condition

Fluid Leaks

Brake Pads (See page 85)

Brake Disc

Parking Brakes (See page 52)

Brake System (See , page 85)

150 MI.

(240 KM)

BRAKES

500 MI.

(800 KM)

I I I I

KM)

1000 MI. (1600

KM)

2000 MI. (3200

PRE- SEASON

Brake Fluid (See page 51,page 86)

FUEL MANAGEMENT

Carburetor (synchronize) (See page

81)

Idle RPM I I I

Throttle Lever (See page 63)

Oil Pump Lever (synchronize)

Choke I I I

Vent Lines I I I I

Fuel / Vent Hoses

Fuel Filter R – Every 2000 mi. (3200 km) or Every 2 years

Oil Filter (See page 80)

I I I I I

I I I

MAINTENANCE

I - INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF NECESSARY) C - CLEAN, R - REPLACE, L - LUBRICATE

FREQUENCY

ITEM

Oil Lines

Air Box

Drain and Water Traps (See page 82)

Auxiliary Shut-Off (See page 54)

Throttle Safety Switch

Ignition Switch

Taillight (See page 54)

Brakelight (See page 54)

150 MI.

(240 KM)

I I I I I

ELECTRICAL

I I I I I

500 MI.

(800 KM)

I I I

KM)

1000 MI. (1600

I I I

KM)

2000 MI. (3200

PRE- SEASON

Headlight (See page 54)

I I I I

MAINTENANCE

I - INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF NECESSARY) C - CLEAN, R - REPLACE, L - LUBRICATE

FREQUENCY

ITEM

Ski Toe Alignment

Suspension Mounting Bolts

Bolt Torques

Steering Fasteners

Rear Suspension Fasteners

Cooling Fan / Ducts / Bulkhead Vent (See page 81)

Skags (Wear Bars) (See page 98)

Ski Saddle/Spindle Bolts

150 MI.

(240 KM)

CHASSIS

I I I I I

See your dealer every 1000 mi. (1600 km) for inspection

I I I I C

I I I I I

500 MI.

(800 KM)

I I I

I I I I

KM)

1000 MI. (1600

KM)

2000 MI. (3200

PRE- SEASON

Steering Arm(s)

Drive Chain Tension (See page 84)

Hood and Side Panel Fasteners (See page 54)

Rear Wheel Idler Bolts

Idler Bolt Jam Nut

Handlebar Centering

Tether Switch and Strap (See page 54)

Track Tension

I I I I I

MAINTENANCE

I - INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF NECESSARY) C - CLEAN, R - REPLACE, L - LUBRICATE

FREQUENCY

ITEM

Track Alignment (See page 96)

Front Limiter Strap

Rail Slide Condition (See page 100)

Chaincase Oil

150 MI.

(240 KM)

CHASSIS

I I I I I

I R I R I

500 MI.

(800 KM)

KM)

1000 MI. (1600

KM)

2000 MI. (3200

BOLT TORQUE INSPECTION

To maintain proper chassis performance, see your POLARIS dealer, or equivalent, for a bolt torque inspections every 1000 miles (1600 km).

ITEM DESCRIPTION

PRE- SEASON

Engine Mounting Bolts

Chaincase Mounting Bolts

Remove drive clutch and resonator for access to all bolts

Two (2) TORX-head bolts on forward side of chaincase

Four (4) rear chaincase nuts

MAINTENANCE

HOOD/SIDE PANEL

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

To open a side panel, do the following:

1. Rotate the two 1/4-turn fasteners, located at the upper edges of the side panel

2. Release the side panel strap at the lower edge of the panelw.

To remove an open side panel:

1. Pull the panel outward to release the tabs at the lower edge of the panel.

Removing the hood is not recommended. Any service requiring the removal of

the hood should be performed by an authorized POLARIS dealer, or equivalent

, counterclockwise.

NOTICE

person.

MAINTENANCE

LUBRICATION

REAR SUSPENSION

Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

Lack of lubrication will adversely affect your ride and the life of the suspension. For more information about suspension lubrication and adjustments, see your POLARIS dealer.

REAR SUSPENSION (144)

REAR SUSPENSION (155)

MAINTENANCE

REAR SUSPENSION (INDY 121 & EVO)

CHAINCASE OIL

Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning pages. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube, or equivalent product.

OIL LEVEL

1. Position the vehicle on a level surface.

2. Remove the fill plug

3. Using a funnel, slowly add the recommended oil until the fluid begins to overflow.

MAINTENANCE

4. Wipe the fill area with a clean cloth.

5. Reinstall the fill plug.

TORQUE

Fill Plug

6-10 ft-lbs (8-13 N·m)

OIL CHANGE

1. Position the vehicle on a level surface.

2. Place a drain pan under the drain plug. Remove the drain plug. Allow the oil to drain completely.

3. Clean off all metal shavings from the plug.

TIP

The sealing surfaces on the drain plug and the chaincase should be clean and

free of burrs, nicks or scratches.

4. Reinstall the drain plug.

TORQUE

Drain Plug

6-10 ft-lbs (8-13 N·m)

5. Remove the fill plug. Clean off all metal shavings from the plug.

6. Using a funnel, slowly add the recommended oil until the fluid begins to overflow. Fluid capacity is 9 oz. (266 ml).

7. Wipe the fill area with a clean cloth.

8. Reinstall the fill plug.

TORQUE

Fill Plug

6-10 ft-lbs (8-13 N·m)

MAINTENANCE

SPARK PLUG

SPARK PLUG RECOMMENDATIONS

It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning. Change the spark plugs every 2000-2500 miles (3200-4000 km)

NOTICE

A spark plug with a heat range too high will always cause engine damage if the

engine is operated in conditions more severe than intended for that plug.

Always use the spark plugs recommended for your snowmobile.

A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization.

• Use recommended spark plugs with the proper gap.

• Use only resistor-type spark plugs.

• Torque spark plugs to specification.

TORQUE

Spark Plug

18-22 ft-lbs (24-30 N·m)

• Always carry spare spark plugs.

SPARK PLUG CONDITION

NORMAL PLUG

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

TIP

The tip should not be white. A white insulator tip indicates overheating, caused

by use of an improper spark plug or incorrect carburetor/throttle body

adjustments.

WET FOULED PLUG

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil or use of non-recommended injection oil.

MAINTENANCE

SPARK PLUG REMOVAL AND REPLACEMENT

Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.

TIP

Incorrect fuel mixture can often cause a spark plug to appear too dark or too

light in color. Before changing spark plug heat ranges, be sure the correct main

jet is installed in the carburetor(s).

WARNING

A hot exhaust system and engine can cause burns. Wear protective gloves

when removing a spark plug for inspection.

1. Remove the left side panel.

2. Remove the spark plug cap.

3. Using the special wrench provided in the tool pouch, rotate the spark plug counter-clockwise to remove it.

4. Reverse the procedure for park plug installation.

TORQUE

Spark Plug

18-22 ft-lbs (24-30 N·m)

5. Reinstall the spark plug cap.

MAINTENANCE

INTAKE FILTERS

NOTICE

Operating the snowmobile with the intake filters removed may cause

carburetor icing. The result will be poor fuel economy or carburetor

malfunction. Always reinstall the intake filters before operating the snowmobile.

The intake filters on the left and right console limit snow ingestion into the intake system. When operating in loose powder snow, check the filters periodically to remove any accumulation of snow.

OIL LINES

Inspect oil line condition every 1000 miles (1600 km).

OIL FILTER

The oil filter is located in-line between the oil tank and oil pump. Have your dealer change the oil filter and bleed the system at the intervals outlined in the Periodic Maintenance Table.

TIP

The direction of the arrows indicates the direction of flow through the filter.

FUEL PUMP

All fuel pump service must be performed by an authorized POLARIS dealer. Do not attempt to service the fuel pump.

MAINTENANCE

FUEL FILTER / FUEL LINES

This snowmobile is not equipped with an in-line fuel filter. The fuel pump uses a sock-type pickup filter located within the fuel tank. This filter should only require maintenance if debris or foreign material enters the fuel tank. An authorized dealer can provide service.

Contaminated or poor quality fuel may shorten the life of fuel system components and result in poor engine performance. Always store fuel in clean fuel containers. If low fuel pressure or reduced engine performance occurs, the filter may need replacement. An authorized dealer can assist.

Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds may occur. Replace worn or damaged fuel lines promptly.

NOTICE

Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines. If a fuel line has been damaged or kinked, replace

it promptly.

COOLING SYSTEM

Inspect the fan intake and outlet ducts for cracks, blockage, obstructions, damaged seals or loosening of the ducts. Make any necessary repairs promptly.

EXHAUST SYSTEM

Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting.

WARNING

Hot exhaust system parts can cause burns. Allow adequate time for the

exhaust system to cool. Never perform this procedure with the engine running.

1. Open the side panels and remove the hood. See page 74

2. Inspect the muffler and pipes for cracks or damage.

3. Check for weak or missing retaining springs or damper/support grommets.

CARBURETOR

The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It’s your dealer’s responsibility to make sure the correct main jet is installed.

MAINTENANCE

NOTICE

Operating the snowmobile with incorrect jetting can result in serious engine

damage. Have your POLARIS dealer perform all carburetor adjustments to

ensure all adjustments are done correctly.

CARBURETOR ADJUSTMENTS

The frequency at which the carburetors are synchronized or balanced is important. Properly adjusted carburetors can greatly improve engine performance, fuel economy, engine life, and reliability.

If you notice any of the following conditions, the carburetor may need adjustment:

• Hard starting

• Poor idle

• Overheated pistons and cylinder walls

• Plug fouling

• Poor engine response to various throttle valve openings

CARBURETOR WATER/SEDIMENT TRAP

Most POLARIS snowmobiles contain patented carburetor bowl water/ sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination.

WARNING

When draining the traps, fuel spillage will occur. Always work in a well

ventilated area away from anything that may cause the fuel to ignite, such as

open flames, sparks, heaters, trouble lights, cigarettes, etc. Review the fuel

warnings on page 59.

CLEANING PROCEDURE

1. Turn the fuel valve off.

2. Position a container or shop towel below the plug to catch drained fuel.

MAINTENANCE

3. Slide the clamp drain plug plug from the sediment tube.

4. Wipe residue from the plug and reinstall it.

5. Reposition the clamp (with the clasp facing outward) and tighten.

6. Repeat the draining procedure for any remaining traps.

and remove the drain

away from the

MAINTENANCE

DRIVE CHAIN TENSION

Check drive chain tension weekly and before each long trip.

1. Remove the side panels.

2. Rotate the driven clutch counter-clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.

3. Loosen the adjuster bolt jam nut

4. Finger tighten the adjuster boltwuntil it can no longer be adjusted by hand, then back off 1/4 turn.

5. Tighten the jam nut while holding the adjuster bolt.

TORQUE

Jam Nut

21 ft-lbs (28 N·m)

6. Reinstall the side panels.

7. Release the brake lever lock.

MAINTENANCE

BRAKES

HYDRAULIC BRAKE INSPECTION

Inspect the brake lever reserve before each use of the snowmobile. See page

51.

Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake pads. See your dealer.

WARNING

Brake failure during operation can result in serious injury or death. Properly

functioning brakes are vital to your safety. Be sure the brake pads do not drag

on the disc and that brake lever travel is not excessive. Always replace brake

pads when the brake pad material becomes thinner than the backing plate

(approximately 1/16 inch or 1.5 mm).

BRAKE COMPONENTS

Brake Caliper

Brake Disc

Brake Pad Material (replace when thickness is less than 1/16 in. or 1.5 mm)

MAINTENANCE

EXCESSIVE LEVER TRAVEL

Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, bring the snowmobile to an authorized POLARIS dealer for inspection and adjustment.

BRAKE FLUID

Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid, or an equivalent product.

WARNING

After opening a bottle of brake fluid, always discard any unused portion. Never

store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly

absorbs moisture from the air. The moisture causes the boiling temperature of

the brake fluid to drop, which can lead to early brake fade and the possibility of

accident or serious injury.

WARNING

Keep the master cylinder cover free of dirt and debris. The vent slits allow for diaphragm movement, and if they become plugged, movement of brake fluid

below the diaphragm may be restricted, altering brake function.

NOTICE

Brake fluid will damage labels, paint and some plastics. Always wipe up spills

immediately.

BLEEDING THE HYDRAULIC BRAKE SYSTEM

Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile.

WARNING

Operating the vehicle with a spongy brake lever can result in loss of brakes,

which could cause an accident and lead to serious injury or death. Never

operate the vehicle with a spongy-feeling brake lever.

CAUTION

Hot exhaust system parts can cause burns. Allow adequate time for the

exhaust system to cool. Never perform this procedure with the engine running.

MAINTENANCE

During the bleeding procedure, keep the brake handle as level as possible. The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent.

1. Remove the brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.

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

WARNING

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

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

fluid to the fill line as recommended.

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

86.

8. Reinstall the gasket and cover.

LIGHTS

When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol.

HEADLIGHT LAMP REPLACEMENT

1. Peel back the foam shield covering the headlight assembly.

2. Remove the wire harness connector from the back of the headlight.

3. Grasp the bulb housing and turn it counter-clockwise to remove the bulb.

4. Apply dielectric grease to the socket and install the new bulb. Rotate the bulb 1/4 turn clockwise to secure it.

5. Reinstall the connector to the back of the headlight.

6. Secure the foam shield.

MAINTENANCE

TAILLIGHT/BRAKE LIGHT REPLACEMENT

The taillight assembly is not serviceable. If the light fails to operate properly, replace the entire taillight assembly.

CLUTCH SYSTEM

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

WARNING

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

vibration or shift pattern, see your dealer or qualified person immediately. Do

not operate the snowmobile until repairs have been made.

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

NOTICE

The slider blocks and bushings of the 550 clutches are made of a material that

may be damaged if lubricated. Do not lubricate bushings or slider blocks.

TORQUE STOP

Periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010-.030 inch (.25-.75 mm) from the engine case.

Adjust if necessary, and lock the jam nut.

DRIVE BELT CONDITION

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

Always carry a spare drive belt. Store the spare belt in the belt clip located under the left side of the hood.

MAINTENANCE

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

DRIVE BELT DEFLECTION

Measure belt deflection with both clutches at rest and in their full neutral position.

Place a straight edge on the belt and apply downward pressure while measuring at point. This measurement should be 1 1/8 - 1 1/4 in. (2.85 - 3.2 cm).

DRIVE BELT DEFLECTION ADJUSTMENT

Adjusting the drive belt deflection is accomplished by turning the driven clutch offset screws inwards to increase deflection, or outwards to decrease deflection. Use the Belt Tension Adjuster Tool to loosen, hold, and tighten the jam nuts.

Belt Tension Adjuster Tool

PN: PS-51272

MAINTENANCE

1. Loosen the two 6 mm jam nuts The adjuster tool is designed to allow access to the adjuster screw while holding the jam nut.

using the Belt Tension Adjuster toole.

NOTICE

Both adjuster screws will need to be turned outwards (counter-clockwise) to

decrease deflection. When making adjustments, only adjust one of the screws.

2. To increase belt deflection, use a 3 mm Allen wrench to turn one of the adjuster screws set screw outwards (counter-clockwise).

3. Make adjustments until drive belt deflection is set to specification.

inwards (clockwise). To decrease belt deflection, turn the

Drive Belt Deflection

1.13-1.25 in (2.85-3.2 cm)

MAINTENANCE

4. After achieving the desired belt deflection, tighten the jam nut to specification while holding the adjuster screw stationary.

5. Turn the remaining adjuster screw inwards until it makes contact with the spacer washer. Turn screw inwards slightly, and then tighten jam nut to specification while holding the adjuster screw stationary.

TORQUE

Driven Clutch Adjustment Screw Jam Nuts

57.5-75 in-lbs (6.5-8.5 N·m)

DRIVE BELT REMOVAL

NOTICE

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

snowmobile must be stopped after forward motion to prevent damage to

components during belt removal. Rotate the driven clutch counter-clockwise 1/

4 turn by hand to ensure forward engagement before attempting to remove the

belt.

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

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

3. Lock the parking brake.

4. Remove the left side panel.

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

6. Locate the L-wrench in the tool kit. Install the wrench into the open threaded hole in the outer sheave of the clutch.

7. Turn the wrench clockwise until the sheaves open far enough to remove the belt. If the wrench does not turn readily, rotate the driven clutch counterclockwise an additional 1/4 turn by hand and try again.

8. Remove the belt from the driven clutch.

MAINTENANCE

DRIVE BELT INSTALLATION

1. With the L-wrench inserted into the threaded hole and the sheaves in the open position, install the drive belt.

TIP

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

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

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

3. Reinstall the side panel.

4. Break in the new belt. See page 58.

TRACK

TRACK INSPECTION

WARNING

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

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

track. Never rotate a damaged track under power.

NOTICE

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

1. Using a hoist, safely lift and support the rear of the snowmobile off the ground.

2. Rotate the track by hand to check for damage.

3. Carefully examine the track along the entire length of each rod Bend the track to check for breakage.

4. Replace the track if any rod damage is found.

MAINTENANCE

TRACK LUBRICATION

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

WARNING

Operating with insufficient lubrication between the rail slide and track guide

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

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

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

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

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

TRACK TENSION

WARNING

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

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

parts. Never perform track measurement or adjustments with the engine

running.

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

TRACK TENSION DATA CHART

Suspension Weight Measurement

Location

144 10 lbs. (4.54 kg) 16 in. (40 cm)

ahead of rear

idler shaft

Slack Measurement

7/8-1 1/8 in. (2.2-

2.9 cm)

155 10 lbs. (4.54 kg) 16 in. (40 cm)

ahead of rear

idler shaft

3/8-1/2 in. (1.0-

1.3 cm)

MAINTENANCE

TRACK TENSION DATA CHART

INDY (121) 10 lbs. (4.54 kg) 16 in. (40 cm)

ahead of rear

idler shaft

INDY EVO 10 lbs. (4.54 kg) 16 in. (40 cm)

ahead of rear

idler shaft

TIP

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

limber.

1. Turn the engine off.

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

3. Place the recommended weight or downward pressure on the track at the specified distance (see chart) ahead of the center of the rear idler wheel.

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

7/8-1 1/8 in. (2.2-

2.9 cm)

7/8-1 1/8 in. (2.2-

2.9 cm)

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

If the track needs adjustment:

6. Loosen the rear idler shaft bolt

7. Loosen the locknutsw.

MAINTENANCE

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

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

TIP

Check more frequently when the snowmobile is new.

10.Start the engine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brakes).

11. Check track alignment (see page 96) and adjust as necessary.

12.Tighten the locknuts.

13.Tighten the idler shaft bolts.

TORQUE

35 ft. lbs. (47.5 Nm)

MAINTENANCE

TRACK ALIGNMENT

Periodically check that the track is centered and running evenly on the slide rails

. Misalignment will cause excessive wear to the track and slide rail.

1. Safely support the rear of the snowmobile with the track off the ground.

2. Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions. Stop the engine and let the track come to a stop (do not apply brakes).

3. Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side. If the track runs to the left, loosen the idler shaft bolt, then loosen the left locknut and tighten the left adjusting bolt. If the track runs to the right, loosen the idler shaft bolt, then loosen the right locknut and tighten the right adjusting bolt.

4. After adjustments are complete, tighten the locknuts.

TORQUE

Locknuts

35 ft-lbs (47.5 N·m)

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

MAINTENANCE

STEERING SYSTEM

STEERING INSPECTION

Each week, or before a long ride, check all steering system fasteners and tighten if necessary.

SKI ALIGNMENT

WARNING

Improper ski alignment or adjustment may cause loss of steering control,

resulting in serious injury or death. Do not attempt to change the ski alignment

or camber adjustment. Your POLARIS dealer can perform this service.

If the steering feels heavy, or if the snowmobile seems to pull or dart to the side, ski alignment may need adjustment. Refer to the service manual, or your dealer, to perform this service.

SKI TOE SETTINGS

WARNING

Improper ski toe adjustment may cause loss of steering control, resulting in

serious injury or death. Do not attempt to change toe adjustment. Your

POLARIS dealer can perform this service.

The skis on your snowmobile are set with a small amount of toe-out at the factory. You can inspect the toe setting by following the procedure below.

SKI TOE MEASUREMENT TABLE

Model Skis Off Ground (Yes/

550 INDY 144 550 INDY LXT 550 INDY Voyageur 550 INDY ADVENTURE

No)

Yes 0-1/8 in.

Difference Between

and

Measurements

(0-3 mm)

550 INDY Voyageur 155 550 INDY ADVENTURE 155

INDY 121 Yes 0-1/8 in.

INDY EVO EVO RMK

No 1/8-1/4 in.

(3-6 cm)

(0-3 mm)

Yes 5/16-3/8 in.

(8-9.5 mm)

MAINTENANCE

1. On some models, measuring ski toe must be done with the skis off the ground. Refer to the ski toe measurement table above.

2. If your model requires lifting the skis off the ground, safely elevate the front end of the snowmobile using a floor jack.

3. If your model does not require lifting the skis, make sure only vehicle weight is compressing the suspension when measuring.

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

5. Measure 10 inches (25.4 cm) forward from the center of the ski mounting bolt

6. Perform the same measurement rearward from the center of the ski mounting bolt. This is measurement

. At this point, measure between the skis. This is measurementq.

7. Theqmeasurement should be greater than the amount shown in the ski toe measurement table. If the skis are misaligned, or if ski toe requires adjustment, your dealer can assist.

measurement by the

SKI SKAGS

See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.

Polaris 550 Indy (2022) Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual