Polaris 550 Indy 144, 550 Indy Adventure, 550 Indy Voyager, 550 Indy LXT User Manual

Download

PMS 419

550 INDY 144

550 INDY LXT

550 INDY Adventure

550 INDY Voyager

Snowmobile Owner's Manual

for Maintenance and Safety

WARNING

Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

WELCOME

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

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• RZR® sport vehicles

• VICTORY® motorcycles

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

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

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

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

The following are registered trademarks of POLARIS Industries Inc.:

POLARIS® INDY® PERC®

Copyright 2013 POLARIS Sales 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. 2014 Owner’s Manual 550 INDY LXT/550 INDY Adventure/550 INDY Voyager/550 INDY 144 P/N 9924266

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

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

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

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 34

This section includes suspension set-up information and explains how to make additional suspension adjustments for the perfect riding experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 42

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 98

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 100

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 101

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 114

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

INTRODUCTION

Important Notes for Owners and Drivers

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

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

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

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

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

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

INTRODUCTION

Preservation of the Environment

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

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

Noise Level

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

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

Air Pollution

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

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

INTRODUCTION

Vehicle Identification Numbers

Record your snowmobile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

Tunnel VIN

Vehicle Model Number: ___________________________________________________

Tunnel VIN (right side of tunnel): ____________________________________________

Engine Serial Number (on recoil housing): ____________________________________

Key Number: ___________________________________________________________

SAFETY

Operator Safety

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

The safety alert symbol indicates a potential personal injury hazard.

DANGER

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

WARNING

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

CAUTION

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

NOTICE

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

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

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

SAFETY

WARNING

Operator Safety

Follow the recommended maintenance program beginning on page 64 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

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

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

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

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

SAFETY

Operator Safety

Stay Clear of Track

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

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

Stay Clear of Engine

Never attempt adjustments with the engine running. 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.

SAFETY

Operator Safety

Riding Apparel

Helmet

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

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

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

Eye Protection

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

Clothing

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

21.

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

051039

0006.31

SAFETY

Operator Safety

Disabled Operators

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

Cargo Overload

Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on a seat back or cargo carrier.

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 while riding. For added protection, purchase and carry the following items on your snowmobile as well:

• Spare Drive Belt • Winter Survival Kit

• Extra Set of Spark Plugs • Trail Map

•Tow Rope •First Aid Kit

• Extra Oil • Tool Kit

• Fuel Deicer

SAFETY

Operator Safety

Rider Capacity

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.

Driving With a Passenger

1. Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

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

3. Perform the suspension adjustments required due to extra rider weight.

4. Make sure any passenger is tall enough to comfortably and safely reach the grab handles and running boards/footrests.

5. Make sure both driver and passenger are wearing appropriate riding gear, including an approved helmet.

6. Perform the recommended pre-ride inspections. See page 42.

7. Lock the parking brake when loading a passenger. Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger mounts or dismounts. Unlock the parking brake before operating.

8. Allow a passenger to ride only in the approved passenger seat.

9. Never carry more than one passenger.

10. Slow down! Control may be more difficult with a passenger on board. Allow more time and distance for braking. Reduce speed when turning.

11. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle.

SAFETY

Operator Safety

Driving With a Passenger

12. A passenger should always be seated in the passenger seat with both feet on the running boards/footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator. Never secure a passenger to the vehicle or to the operator with a belt, rope or similar device.

13. Make sure the passenger understands the importance of “active riding.” When turning or performing maneuvers, a passenger should shift body weight in the same manner in which the driver shifts body weight. For example, the passenger should lean to the inside of a turn along with the driver.

14. Make sure your passenger has read and understands the instructions and warnings in this manual.

15. Never remove your hands from the handlebars while operating, and always keep both feet on the running boards/footrests.

Passenger’s Responsibilities

1. Read and understand this owner’s manual. Review all warnings and labels.

2. Always remain seated in the passenger seat and facing forward, with hands grasping the passenger hand holds and both feet placed firmly on the running boards/footrests.

3. Tell the driver to slow down or stop if you are uncomfortable. Do not continue to ride on the vehicle if you cannot comfortably follow all instructions in this manual.

4. Always use an approved helmet and protective gear when riding.

5. During turns and maneuvers, shift your body weight in the same manner in which the driver shifts body weight.

SAFETY

Operator Safety

Driver Awareness

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

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

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

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

SAFETY

Operator Safety

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.

Driving on Slippery Surfaces

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

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

Maneuverability

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

SAFETY

Operator Safety

Avalanches

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

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

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

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.

SAFETY

Operator Safety

Ice and Snow Build-up

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

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

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

Inadequate Snow Conditions

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

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

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

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.

the slide rail, track and/or engine.

SAFETY

Operator Safety

Driving Downhill

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

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

Driving in Hilly Terrain

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

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

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

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

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

SAFETY

Operator Safety

Drive Belt

Do not operate the engine with the drive belt removed.

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

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

Intake Silencer

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

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

Clutches

Do not attempt to service the clutches.

All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from ice and snow before attempting to drive. Apply the throttle with enough authority to put the snowmobile into motion, but always operate within safety limits and, on 2-up machines, with respect for a passenger.

damage to the engine.

removed.

SAFETY

Operator Safety

Driving Responsibly

Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under various conditions. Even seasoned drivers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.

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

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

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

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

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

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

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WINDCHILL CHART (°F)

Wind

Speed

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

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

5 3631251913 7 1 -5-11-16 10 34 27 21 15 9 3 -4 -10 -16 15 32 25 19 13 6 0 -7 -13 20 30 24 17 11 4 -2 -9 -15 25 29 23 16 9 3 -4 -11 -17 30 28 22 15 8 1 -5 -12 35 28 21 14 7 0 -7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89 40 27 20 13 6 -1 -8 -15 45 26 19 12 5 -2 -9 -16 50 26 19 12 4 -3 -10 -17 55 25 18 11 4 -3 -11 60 25 17 10 3 -4 -11

Frostbite in >>

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

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

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

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

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

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

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

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

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

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

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

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

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

30 min. 10 min. 5 min.

WINDCHILL CHART (°C)

Wind

Speed

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

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

8 3 0 -4 -7 -11 -14 -18 -22 -25 -29 16 2 -2 -6 -10 -13 -17 -21 -24 -28 24 1 -3 -7 -11 -15 -19 -22 -26 32 0 -4 -8 -12 -16 -20 -24 -28 40 -1 -5 -9 -13 -17 -21 -25 -29 48 -1 -5 -9 -13 -18 -22 -26 56 -2 -6 -10 -14 -18 -22 -26 64 -2 -6 -10 -15 -19 -23 -27 72 -2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74 80 -3 -7 -11 -15 -20 -24 -28 88 -3 -7 -12 -16 -20 -24 96 -3 -8 -12 -16 -21 -25

Frostbite in >>

Actual Thermometer Reading (°C)

Equivalent Temperature (°C)

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

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

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

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

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

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

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

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

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

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

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

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

30 min. 10 min. 5 min.

SAFETY

Safety Labels and Locations

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

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

Clutch Warning/Belt Removal

This warning label is found on the clutch cover:

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.

Clutch Warning

SAFETY

Reverse Warning

“One Passenger”

Warning

“No Passenger”

Warning

Safety Labels and Locations

No Passenger Warning (One Rider Models)

WARNING

This vehicle is designed for operator only. NO PASSENGER.

Passenger Warning (Passenger Models)

WARNING

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

Reverse Warning

WARNING

Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always:

• Look behind before and while backing up.

• Avoid sharp turns.

• Shift to or from reverse only when stopped.

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

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

• Push button again to return to forward.

SAFETY

Safety Labels and Locations

Operation Warning

WARNING

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

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

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

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

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

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

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

(continued on next page)

SAFETY

Safety Labels and Locations

Operation Warning

• When operating with a passenger (on approved models only) reduce speed

and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle.

• When operating on hard-packed snow, ice, or when crossing roads, steering

and braking ability are greatly reduced. Reduce speed and allow extra space to turn or stop.

• To maintain vehicle control on ice or hard-packed surfaces, you should have

a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products.

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

ability.

• Parking brake may relax when used for long periods. Do not leave brake

engaged for more than five minutes.

• Before starting engine, check throttle, brake, and steering for proper opera-

tion. Make sure hood and side panels are latched. Be seated and in position to control the vehicle.

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

Track Warning

WARNING

Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death.

Track Warning

FEATURES

4. Nosepan

5. Skis

6. Front Bumper

7. Hood

8. Headlight

9. Windshield (if equipped)

10. Handlebar

11. Fuel Filler Cap

12. Operator Seat

13. Passenger Seat (if equipped)

14. Passenger Backrest (if equipped)

15. Cargo Rack (if equipped)

16. Taillight

17. Rear Bumper

18. Snow Flap

19. Suspension

20. Track

21. Side Panel

22. Side Panel Fasteners

FEATURES

1. Instrument Cluster

2. Ignition Switch

3. Engine Stop Switch

4. Recoil Starter Handle

5. Brake Lever

6. Parking Brake Lock

7. Handlebar Grip Warmer Switch

8. Thumbwarmer Switch

9. Electronic Reverse Button

10. Headlight Dimmer Switch

11. Tool Kit/Storage Bag

FEATURES

Down

Adjustment Positions

Cargo Area

Adjustable Headlights

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

Passenger Grab Handle

If equipped, the passenger grab handles can be adjusted for rider preference.

1. Remove the hardware securing the grab handles to the grab handle tube.

2. Reposition the grab handles to one of the three available positions and reinstall the hardware securely.

Cargo Storage

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

FEATURES

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:

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others This applies, 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.

FEATURES

Instrument Cluster

Speedometer

Rider

Information

Center

Indicator

Lamps

MODE Button

The instrument cluster contains the speedometer, indicator lamps, MODE button and rider information center.

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.

Speedometer

The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h).

Instrument Cluster

Indicator Lamps

Lamp Indicates Condition

Vehicle Speed

Reverse This indicator flashes when the transmission

High Beam The high beam indicator illuminates when the

Parking Brake This indicator illuminates when the parking

Low Oil The low oil indicator light may flicker at times

When standard mode is selected, speed displays in miles per hour.

When metric mode is selected, speed displays in kilometers per hour.

is in reverse. See page 60.

lights are set to high beam.

brake is engaged. It will also illuminate when the service brake is in use. See page 46.

due to oil movement in the bottle, but when the light comes on and remains on while at idle, add the recommended oil before further operation. See page 56.

FEATURES

Odometer/Engine Hour

Display

Information Display

Instrument Cluster

Rider Information Center

The information center is controlled by the MODE button on the instrument cluster. Use the MODE button to toggle through the available modes. 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 at the factory. To change to metric, see page 33.

Trip 12

RPM

ODO

MODE Button

Information Display Area

This area displays either engine speed, engine temperature or maximum vehicle speed.

Odometer/Engine Hour Display

This area displays the odometer, trip meters and engine hours.

FEATURES

Instrument Cluster

Rider Information Center

Display Units (Standard/Metric)

The display can be changed to display either standard or metric units of measurement. While in the engine temperature display, press and hold the MODE button to change units.

Standard Display Metric Display

Distance Miles Kilometers

Odometer Mode

The odometer records and displays the distance traveled by the vehicle.

Trip Meter Mode

The trip meter records the distance traveled by the vehicle if reset before each trip. T o reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Tachometer Mode

The engine RPM is displayed digitally.

Tip: Small fluctuations in the RPM from day to day may be normal because of

changes in humidity, temperature and elevation.

THE PERFECT FIT

Front Suspension Adjustments

Independent Front Suspension (IFS)

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

1. Skis

2. Front shocks and springs

3. Rod ends

4. A-arms

IFS Adjustment Options

• Front shock spring preload

• Optional springs

THE PERFECT FIT

Measure

Low

Preload

High

Preload

Front Suspension Adjustments

IFS Shock Spring Preload

Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment.

Always perform shock spring preload adjustments with the weight of the vehicle removed from the shock and with the shock at full extension.

To change shock spring preload, grasp the spring retainer and rotate it.

Initial IFS Preload Setting

(from body end to spring)

Ryde FX shocks 4.375" (11.1 cm)

Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension. Never exceed one inch (2.54 cm) of preload beyond the factory settings.

NOTICE: When decreasing preload, make sure

TIP:Other spring options are available. Please

at least two turns of preload are 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.

see your POLARIS dealer.

THE PERFECT FIT

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 see your POLARIS dealer for 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, see your dealer.

THE PERFECT FIT

Rear Suspension Adjustments

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 setup. These adjustments are easy to make, involve very little time or effort, and greatly affect the ride. Always perform shock spring preload

adjustments with the weight of the vehicle removed from the shock and with the shock at full extension.

• In deep snow, a new rail slide will offer improved performance over 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 machine'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. Refer to the Pre-Ride Suspension Inspection on page 43.

Track Tension

Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Refer to the track tension maintenance section beginning on page 86.

THE PERFECT FIT

Installed Length

Measurement

Rear Suspension Adjustments

Rear Track Shock Spring

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. 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 page 39 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 length shown in the chart.

Adjusting beyond maximum adjustment will cause the spring to bottom and result in damage to your rear suspension.

THE PERFECT FIT

Rear Suspension Adjustments

Rear Track Shock Spring

Adjust the rear track shock spring per the chart below.

REAR TRACK SHOCK SPRING (RTSS) SET-UP

(Standard S pring)

Measure spring length with suspension off the ground

Rider Weight

(including all

riders, gear, cargo,

& accessories)

Shaded cells indicate factory settings.

Lbs. kg Inches cm

<160 <73 550 INDY Adventure/Voyager/

LXT 550 INDY 144"

160-220 73-100 550 INDY Adventure/Voyager/

LXT 550 INDY 144"

220-280 100-127 550 INDY Adventure/Voyager/

LXT 550 INDY 144"

280-340 127-154 550 INDY Adventure/Voyager/

LXT 550 INDY 144"

340-360 154-163 550 INDY Adventure/Voyager/

LXT

Model Installed Spring

Maximum

Adjustment

Maximum

Adjustment

Length

(rear suspension off the

ground)

11 1/8 28.2

10 3/4 27.3 10 1/2 26.7

10 1/2 26.7 10 1/8 25.7

10 1/8 25.7

9 3/4

9 7/8

24.7

Maximum

Adjustment

Maximum

Adjustment

THE PERFECT FIT

Tr action 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 91.

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

Loosen bolts to adjust

handlebar angle

Handlebar Adjustments

Handlebar Angle

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

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, loosen the set screws for the left and right controls, rotate the controls slightly, then tighten the set screws to the proper torque.

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

4. Tighten the bolts.

could damage the handwarmers.

• Right control torque: 35 in. lbs. (4 Nm) +/- 10%.

• Left control torque: 24 in. lbs. (2.7 Nm) +/- 10%.

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 83 Steering System 47 Recoil Rope 47 Chaincase Oil Level 70 Injection Oil Level 56 Parking Brake Lock/Brake Lever/Brake System 45-46, 78 Auxiliary Shut-Off Switch (Engine Stop Switch) 48 Ignition Switch 48 Headlight/Taillight/Brakelight 48 Suspension Mounting Bolts 43 Skags (Wear Bars) 91 Ski Saddle and Spindle Bolts 43 Hood and Side Panel Fasteners 68 Throttle Lever/Safety Switch 58, 44 Rear Wheel Idler Bolts 87 Tether Switch/Strap (if equipped) 48 Track Alignment/Condition 47, 88 Rail Slide Condition 91

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 Check Page

Suspension mounting bolts Tightness -Rear idler wheel bolts Tightness 87 Rear idler adjusting bolt locknuts Tightness -Torque arm bolts Tightness -Carrier and bogie wheel bolts Tightness -Front torque arm limiter strap Condition -Rail slide Condition 91 Track Tension 86 All rear suspension components Lubrication 69 Ski runner/skag Condition 91 Ski spindle bolts Tightness -Tie rod end nuts Tightness --

PRE-RIDE INSPECTIONS

Before Starting the Engine

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

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

Read and Understand Your Owner's Manual

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

Throttle Lever

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

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

Throttle Safety Switch

T est the throttle safety switch system before the snowmobile is operated. See page 58.

PRE-RIDE INSPECTIONS

1/2 in. (1.3 cm)

Before Starting the Engine

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 1/2 inch (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 80 or see your dealer for service.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See page 79.

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.

PRE-RIDE INSPECTIONS

Before Starting the Engine

Parking Brake Lever Lock

Use the parking brake lever lock only when you want the snowmobile to remain stationary;

for example, when parked on an incline for a period of five minutes or less.

1. Brake Lever

2. Parking Brake Lever Lock

3. Master Cylinder Reservoir/ Cover

4. Fluid Level Indicator

Lock Engagement

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

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

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

The parking brake light 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.

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

PRE-RIDE INSPECTIONS

Before Starting the Engine

Steering System

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

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

Track

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

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

WARNING! Use of traction products such as studs increases the possibility of track damage and/or failure. Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods, break track edges, and cause other track damage. Examples of marginal lubrication would include frozen bodies of water without snow cover, icy trails, and no-snow conditions.

Hood and Side Panel Fasteners

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.

Seat Latches

If your snowmobile is equipped with a removable seat, ensure that the seat is properly installed and securely latched before each use of the snowmobile.

Recoil Rope

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

PRE-RIDE INSPECTIONS

St art the Engine and Check

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Before Starting the Engine beginning on page 44.

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

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

1. Turn the fuel valve on. See

2. Turn the key to the ON

3. Pull the engine stop switch

4. If starting a cold engine,

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

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

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

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

8. After the engine starts, flip the choke toggle to the OFF position. If

9. Before turning the engine off, operate the choke intermittently to

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

page 55.

position.

CHOKE POSITIONS

FULL CHOKE

up to the RUN position.

1/2 CHOKE

flip the choke toggle to FULL CHOKE. Do not use the choke if starting a warm

OFF

engine. Do not depress the throttle until the engine starts.

it to snap back into the housing. Damage may result.

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

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

the engine slows or wants to stop, use intermittent choking to the HALF CHOKE position.

draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen.

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 58 for more information about the engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES

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

THROTTLE

CONDITION

OPERATION

Break-In Period

Engine Break-In

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

Premix the first tank of fuel and fill the oil bottle with the recommended oil. Oil added to the fuel and oil injection systems will provide the necessary engine lubrication.

Oil Recommendations

First Tank of Fuel: POLARIS Premium Blue 2-Cycle Semi-Synthetic Oil After Break-in: POLARIS Premium Blue 2-Cycle Semi-Synthetic Oil

Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. Oils may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All POLARIS oils are compatible with each other.

Initial Fuel Premix

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

Fuel Premium Blue 2-Cycle

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

Semi-Synthetic Oil

Ratio

OPERATION

Break-In Period

Engine Break-In

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

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

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

Oil Injection System

Always check and fill the oil bottle when refueling. See page 56.

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

Drive Belt Break-In

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

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

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

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.

OPERATION

Tr ack 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.

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.

OPERATION

WARNING

Fuel

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

• Always turn off the engine before refueling.

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

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

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

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

• Turn the fuel valve off whenever the snowmobile is stored, parked or transported.

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).

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.

OPERATION

OFF

Fuel System Deicers

If you use non-ethanol fuel (sometimes labeled “non-oxygenated”), POLARIS recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline to prevent damage resulting from fuel system icing. Never use deicers or additives containing methanol. POLARIS recommends the use of Carbon Clean. See page 100 for the part numbers of POLARIS products.

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

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.

Oil

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 page 51 for oil recommendations.

OPERATION

Bottle Neck

ADD Mark

Oil

Low Oil Level

Always maintain the oil level between the “add” mark and the bottle neck. Do not fill the bottle neck. See page 51 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

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

Carburetion

NOTICE: Making non-recommended adjustments could result in vehicle or

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.

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

engine damage as well as denial of warranty claims. We recommend that all carburetor adjustments be performed by your POLARIS dealer.

OPERATION

Carburetion

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 re-calibrated 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 75 for more information.

NOTICE: A main jet that's too small will cause a lean operating condition and

TIP:It's the owner's responsibility to ensure that the correct jets are installed in

may cause serious engine damage. Jet the carburetors carefully for elevation and temperature according to the jetting charts. See the specifications section beginning on page 98.

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 upward 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

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.

WARNING! Operating the snowmobile with a faulty throttle safe ty 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.

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.

Stop

Switch

OPERATION

Throttle Lever

WARNING! An improperly functioning throttle lever may cause erratic

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

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

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor/throttle body to

determine what caused the safety switch to activate.

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

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

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

go through normal starting procedures.

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

POLARIS dealer for service.

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.

OPERATION

WARNING

Electronic Reverse (PERC)

Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase 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.

Engaging Reverse

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

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

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

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

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

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

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 transmission is in reverse.

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

restarted.

OPERATION

Electronic Reverse (PERC)

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

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

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 instrument panel flashes rapidly, then release the button.

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.

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

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

forward.

OPERATION

Daily Storage

At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 inches (10 cm) off the ground.

Remove the key and cover the snowmobile.

Towing

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

WARNING! Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in serious injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a rope. Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used. If passengers are to be towed on a toboggan or sled, make sure the pole is at least four feet (1.2 meters) long to prevent any possibility of contact between the snowmobile's track and a person riding in the towed object.

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

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

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

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

MAINTENANCE

Emission Control Information

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

Emission Control Label

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

Emission Control Maintenance Requirements

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

Owner's Responsibilities

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

Non-ionizing Radiation

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

MAINTENANCE

POLARIS Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 114.

The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1000 miles (1600 km). These inspections should be performed by a qualified service technician. For continued optimum performance and component life, continue maintenance checks at 1000 mile (1600 km) intervals.

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

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

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

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

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

MAINTENANCE

Periodic Maintenance Interval Table

The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine POLARIS parts, available from your POLARIS dealer.

Item See

Drive Belt Condition 83 II II Clutches 82 CC C Belt Tension -- IIII Clutch Sheaves 82 IIII

Engine Mounts -- IIII Engine Torque Stop 82 IIII Recoil Rope -- IIII Cylinder Head Bolts -- III Cylinder Base Nuts -- III Ignition Timing BTDC -- III Spark Plugs 72 IIRI Exhaust Pipe 74 II Exhaust Retaining

Springs

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

Page

150 mi.

(240 km)

74 IIII

CLUTCH

ENGINE

500 mi.

(800 km)

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Hose Routing -- IIII Hose Condition -- II II Fluid Leaks -- II II Brake Pads 78 IIII Brake Disc -- IIII Parking Brakes 46 IIII Brake System 45, 78 I Brake Fluid 79 I

Pilot Air Screws -- III Carburetor

(synchronize) Idle RPM -- III Throttle Lever 44 III I I Oil Pump Lever

(synchronize) Choke -- III Vent Lines -- IIII Fuel Lines 74 IIII Fuel Filter 74 R - Every 2000 mi. (3200 km) or Every 2 years Oil Filter 73 R Oil Lines 73 III Air Box -- III I I Drain and Water Traps 76 III

Auxiliary Shut-Off Switch

Throttle Safety Switch 58 III II Ignition Switch -- II I I I Taillight 48 II I II Brakelight 48 II I I I Headlight 48 III II

Page

150 mi.

(240 km)

FUEL MANAGEMENT

75 III

-- III

ELECTRICAL

48 II I II

500 mi.

(800 km)

BRAKES

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Ski Toe Alignment -- III Suspension Mounting

Bolts Bolt Torques See your dealer every 1000 mi. (1600 km) for inspection Rear Suspension

Fasteners Steering Fasteners -- III IC Suspension Shock Oil -- R Cooling System 74 II II Drive Shaft Bearing 69 LLL I Jackshaft Bearings 96 LLLI Skags (Wear Bars) 91 III I I Ski Saddle/Spindle Bolts -- III II Steering Arm(s) -- I Drive Chain Tension 77 III I I Hood and Side Panel

Fasteners Rear Wheel Idler Bolts 87 III II Idler Bolt Jam Nut 87 II I II Rear Suspension Pivot

Shafts Camber Alignment -- III Handlebar Centering -- I Tether Switch and Strap 48 III II Track Alignment 88 II I II Track Tension 86 III II Front Limiter Strap -- III II Rail Slide Condition 91 I Chaincase Oil 70 IRI RI

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

Page

150 mi.

(240 km)

-- III II

68 II I II

69 LL L

500 mi.

(800 km)

CHASSIS

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

Bolt Torque Inspection

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

Item Description

Engine Mounting Bolts Remove drive clutch and resonator for access to all bolts Chaincase Mounting Bolts Two (2) TORX-head bolts on forward side of chaincase

Four (4) rear chaincase nuts

MAINTENANCE

Strap

1/4-Turn Fasteners

Hood/Side Panel

T o open a side panel, r otate the two 1/4-turn fasteners at the upper edges of the side panel. Release the side panel strap at the lower edge of the panel.

To remove an open side panel, 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.

MAINTENANCE

Fitting

Lubrication

Rear Suspension

Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 65 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.

INDY Rear Suspension (144)

Driveshaft Bearing

Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps.

MAINTENANCE

Fill Plug

Lubrication

Chaincase Oil

Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning on page 64. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube. See page 100 for the part numbers of POLARIS products.

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.

4. Wipe the fill area with a clean

cloth.

5. Reinstall the fill plug. Torque to

6-10 ft. lbs. (8-13 Nm).

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 oil tank should be clean and

free of burrs, nicks or scratches.

4. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).

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 to 6-10 ft. lbs. (8-13 Nm).

MAINTENANCE

Spark Plugs

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 (32004000 km).

NOTICE: A spark plug with a heat range too high will always cause engine dam-

A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. A v oid 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 18-22 ft. lbs. (24-30 Nm).

• Always carry spare spark plugs.

age if the engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile. See the specifications section beginning on page 98.

MAINTENANCE

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, use of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments.

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).

CAUTION! 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.

4. Reverse the procedure for spark plug installation. Torque to

specification.

5. Reinstall the spark plug cap

MAINTENANCE

Intake

Filter

Intake Filters

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.

NOTICE: Operating the snowmobile with the intake filters removed may cause

Fuel Pump

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

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 T able beginning on page 65.

TIP:The direction of the arrows indicates the

carburetor icing. The result will be poor fuel economy or carburetor malfunction. Always reinstall the intake filters before operating the snowmobile.

direction of flow through the filter.

MAINTENANCE

Fuel Filter/Fuel Lines

See your POLARIS dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page

65.

Contaminated or poor quality fuel will shorten the life of the fuel filter and result in poor engine performance. Always store fuel in clean fuel containers. If low fuel pressure or reduced engine performance occurs between the recommended fuel filter service intervals, the filter may need replacement. See your dealer.

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.

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.

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.

1. Open the side panels and remove the hood. See page 68.

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

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

grommets.

MAINTENANCE

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.

NOTICE: Operating the snowmobile with incorrect jetting can result in serio us

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 at various throttle valve openings

engine damage. Have your POLARIS dealer perform all carburetor adjustments to ensure all adjustments are done correctly.

MAINTENANCE

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 54.

Cleaning Procedure

1. Turn the fuel valve off.

2. Place a container or shop

towels below the plug to catch drained fuel.

3. Slide the clamp (1) away

from the drain plug (2) and remove the drain plug from the sediment tube.

4. Wipe residue from the plug and reinstall it. Reposition and tighten

the clamp.

5. Repeat the draining procedure for any remaining traps.

MAINTENANCE

Jam

Nut

Adjuster

Bolt

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 bolt

until 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 to 21 ft. lbs. (28 Nm).

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 45.

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

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material (Replace

when thickness is less than 1/16 inch or 1.5 mm).

4. Anti-rattle springs (come

with brake pad kit)

Excessive Lever Travel

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

MAINTENANCE

Brakes

Brake Fluid

The brake fluid level can be seen through a plastic sight glass in the brake reservoir. If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid.

Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid. See page 100 for the part numbers of POLARIS products.

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.

MAINTENANCE

Brakes

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.

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 between the MIN and MAX

marks or 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 and 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 79.

8. Reinstall the gasket and cover.

MAINTENANCE

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. Remove the hood.

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. Reinstall the hood.

Taillight/Brake Light Replacement

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

MAINTENANCE

.010-.030 inch (.25-.75 mm)

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 engageme nt or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the snowmobile until repairs have been made.

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

NOTICE: The bushings in the weights and ro llers of POLARIS clutches are

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.

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

MAINTENANCE

Clutch System

Drive Belt Condition

Periodically check the condition and tension of the drive belt. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 105.

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

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

Drive Belt Deflection

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

Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (3.2 cm).

Drive Belt Adjustment

1. Loosen the two 6mm jam nuts on the belt width adjuster.

2. Using a 3mm Allen wrench, turn the set screw inward (clockwise)

to increase the distance between the sheaves or outward (counterclockwise) to decrease the distance.

3. Tighten the jam nuts.

MAINTENANCE

Clutch System

Drive Belt Removal

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

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

2. Remove the left side panel.

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

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

5. Turn the wrench clockwise until the sheaves open far enough to

6. Remove the belt from the driven clutch.

Drive Belt Installation

1. With the L-wrench inserted into

TIP:Install the belt so that the numbers can

2. Wiggle the belt to remove slack

3. Reinstall the side panel.

4. Break in the new belt. See page 52.

snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure forward engagement before attempting to remove the belt.

ignition key off. Wait for the engine to come to a complete stop. Lock the parking brake.

ensure forward engagement.

threaded hole in the outer sheave of the clutch.

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

the threaded hole and the sheaves in the open position, install the drive belt.

be read correctly on the le ft sid e of the vehicle, or in the direction in which the belt was originally installed.

while removing the L-wrench.

MAINTENANCE

Tr ack Maintenance

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.

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.

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. See your dealer for more information.

Rod

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

MAINTENANCE

Tr ack Maintenance

WARNING! Moving parts can cut and crush body parts. When performing the

checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running.

Track Tension

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

TRACK TENSION DATA CHART

Suspension Weight

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

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

limber.

Measurement

Location

ahead of rear

idler shaft

Slack

Measurement

7/8-1 1/8 in. (2.2-2.9 cm)

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.

MAINTENANCE

Slack Measurement

Lock Nut

Adjusting Screw

Track

10 lbs. (4.54 kg)

Shaft

Bolt

16 inches

(40 cm)

Tr ack Maintenance

Track Tension

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

and the plastic slider. Refer to the Track Tension Data Chart on page

86.

If the track needs adjustment:

6. Loosen the rear idler shaft bolt.

7. Loosen the locknuts.

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

adjustment on both sides of the track.

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

TIP:Check more frequently when the snowmobile is new.

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

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

11. Check track alignment (see page 88) and adjust as necessary.

12. Tighten the locknuts.

13. Tighten the idler shaft bolts.

14. Torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).

MAINTENANCE

Tr ack 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 bolts, then loosen the left locknut and tighten the left adjusting bolt. If the track runs to the right, loosen the idler shaft bolts, then loosen the right locknut and tighten the right adjusting bolt.

4. After adjustments are

complete, tighten the locknuts and torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).

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

Rail

MAINTENANCE

Steering System

Steering Inspection

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

MAINTENANCE

10 in.

(25.4 cm)

10 in.

(25.4 cm)

Steering System

Ski Alignment Inspection

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. See your POLARIS dealer.

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

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

inches (25.4 cm) forward from the center of the ski mounting bolt. See illustration. At this point, measure between the skis. This is measurement X.

3. Perform the same measurement rearward from the center of the ski

mounting bolt. This is measurement Y.

4. The X measurement should be 1/8-1/4 inch (3-6 mm) greater than

the Y measurement. If the skis are misaligned, see your dealer for alignment correction as camber adjustment may also be affected.

MAINTENANCE

Skag

Replace when

worn to top of

groove

Minimum

Thickness

Steering System

Ski Skags

WARNING! Worn skis and/or skags will adversely affect handling. Loss of

vehicle control may result, causing serious injury or death. 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.

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

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

Skag Replacement

1. Raise and support the front of the

snowmobile so the skis are approximately 6 inches (15.2 cm) from the ground.

2. Remove the attaching nuts and pry

the skag downward.

3. Remove the front end of the skag.

4. Remove the rear end of the skag.

5. Reverse the steps to install a skag.

Rail Slide Wear

For ease of inspection, all POLARIS rail slides have a wear limit indicator groove to indicate the minimum permissible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Failure to do so may result in permanent damage to the track or rails.

MAINTENANCE

Battery (if equipped)

WARNING! Improperly connecting or disconnecting battery cables can result in

an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

Battery Removal

1. Remove the right side panel to access the battery. See page 68.

2. Disconnect the black (negative) battery cable first.

3. Disconnect the red (positive) battery cable last.

4. Remove the battery.

Battery Installation

When installing a new battery, make sure it's fully charged prior to its initial use. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 94 before installing the battery.

1. Ensure that the battery is fully charged.

2. Set the battery in the battery holder.

3. Connect and tighten the red (positive) cable first.

4. Connect and tighten the black (negative) cable last.

5. Verify that cables are properly routed.

6. Reinstall the side panel.

MAINTENANCE

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

Tip: Battery charge can be maintained by using a POLARIS Battery Tender™

charger (PN 2871076) or by charging about once a month to make up for normal self-discharge. Battery Tender™ can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.

Battery Charging

The following battery charging instructions apply only to the installation of a sealed battery . Read all instru ctions before proceeding with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Do not ever pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage.

MAINTENANCE

Battery

Battery Charging

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully

charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps

or less until the battery voltage is 12.8 or greater.

Tip: When using an automatic charger, refer to the charger manufacturer's

instructions for recharging. When using a constant current charger, use the following guidelines for recharging.

WARNING! An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charg ing if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

Tip: Always verify battery condition before and 1-2 hours after the end of

charging.

State of

Charge

100% 12.8-13.0 volts None, check at 3

75%-100% 12.5-12.8 volts May need slight

50%-75% 12.0-12.5 volts Needs charge 5-11 hours 25%-50% 11.5-12.0 volts Needs charge At least 13 hours,

0%-25% 11.5 volts or less Needs charge with

Voltage Action

mos. from date of

manufacture charge, if no

charge given,

check in 3 months

desulfating charger

Charge Time

(Using constant current charger @ standard amps specified on top of battery)

None required

3-6 hours

verify state of charge

At least 20 hours

MAINTENANCE

Fall Tune-Up

For maximum performance, arrange for a fall service tune-up with your POLARIS dealer. His experienced and trained service technician will keep your snowmobile in peak operating condition.

Transporting the Snowmobile

Whenever the snowmobile is transported:

1. Turn the fuel valve off. See page 55.

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

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

4. Remove the ignition key to prevent loss.

Extended Storage

Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 100 for the part numbers of POLARIS products.

Cleaning and Preservation

Proper storage starts with cleaning, washing, and waxing the hood, side panels, chassis, and plastic parts. Wipe down remaining surfaces with a damp cloth. Clean and touch up with paint any rusted or previously painted surfaces. Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors (grease, oil or paint).

The snowmobile should be stored in a dry garage or shed, out of direct sunlight, and covered with a fabric snowmobile cover. Plastic tarp may cause condensation to form and damage snowmobile components.

MAINTENANCE

Extended Storage

Controls and Linkage

Lubricate all bushings and cables as outlined in the Periodic Maintenance Table beginning on page 65.

Bearings

Grease the jackshaft and drive shaft clutch side bearings with POLARIS All Season Grease or a similar high quality grease to prevent corrosion.

Battery Maintenance

Remove the battery and recharge it as outlined on page 94. Store the battery in a cool, dry place.

Clutch and Drive System

Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer.

MAINTENANCE

Extended Storage

Engine and Carburetor Protection

Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on precision engine parts during storage. Whenever the machine is stored for a period of more than 60 days, the engine must be fogged with fogging oil.

1. Always add Carbon Clean to the fuel tank.

2. Run the engine for 10-15 minutes.

3. With the engine still running, turn the fuel valve off and spray the engine with fogging oil. Follow the instructions on the container.

4. Allow the engine to stop by itself.

If stabilizer is not used, drain the carburetors by removing the water trap drain plugs. See page 76.

TIP:Jet restriction caused by improper storage can cause lean conditions and

very poor slow speed driving quality.

Electrical Connections

Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts.

Track and Suspension

Moderate track tension should be maintained during summer storage. The snowmobile should be supported off the ground to allow the track to hang freely.

SPECIFICATIONS

550 INDY 144/Voyager/Adventure/LXT

Capacities and Dimensions

Body Style INDY Rider Capacity 1 Rider (144/Adventure)

Fuel Capacity 11.5 gal. (43.5 l) Oil Capacity 3.05 qts. (2.89 l) Gearcase Oil Capacity N/A Length 124.5 in. (316.2 cm) (144/Adventure/LXT)

Width 48 in. (122 cm) (144/Adventure/LXT)

Height Range 46.5-52 in. (118-132 cm) Brake Type Hayes Phantom Lite DOT 4 Drive Clutch Center Distance 10.63 in. (27 cm) Drive Belt P/N 3211154 Drive Clutch / Driven Clutch CVTech PB50 / CVTech Invance Reverse Transmission Electronic Reverse

Engine EC550PM0130 Displacement 544 cc Cylinders 2 Bore x Stroke (mm) 73.0 x 65.0 Alternator Output 280 watt Carburetor/Throttle Body 2-Mikuni Carburetor Model VM34 Idle RPM 1700 +/- 200 Rated Operating RPM 7000 +/- 200 Cooling Fan Air Ignition Type Kokusan 16 Bit ER Ignition Timing 15° BTDC @ 1600 RPM, 17° BTDC @ 6500 RPM Spark Plug / Gap NGK BR9ES / .028 in. (0.70 mm)

Recommended Fuel Octane Minimum 87 non-oxygenated

Main Jet 220 Pilot Jet 45 Jet Needle/Clip Position 6BGY48/#4 Needle Jet Q-0 (480) Cutaway 3 Throttle Gap Under CA 6.98 mm / .275 in. Fuel Screw (from fully seated) N/A Air Screw (from fully seated) 1.5 Turns Pilot Air Jet 2.5

2 Riders (Voyager/LXT)

131.5 in. (334 cm) (Voyager)

46.5 in. (118 cm) (Voyager)

Engine and Cooling

Carburetor Settings

Polaris 550 Indy 144, 550 Indy Adventure, 550 Indy Voyager, 550 Indy LXT User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual