Polaris 600 Dragon SP, 800 Dragon SP, IQ Shift 136 User Manual

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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 worldwide family of Polaris enthusiasts. Be sure to visit us online at www.polarisindustries.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)

• RANGER utility vehicles

• Victory motorcycles

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.

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

Copyright 2008 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.

Printed in U.S.A.

2009 Owner's Manual P/N 9921220 600 IQ/IQ Shift 136/600 Switchback/600 Dragon Switchback/600 Dragon SP 800 IQ/800 Switchback/800 Dragon Switchback/800 Dragon SP

TABLE OF CONTENTS

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

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 41

This section explains how to tailor the suspension and other features for an optimum riding experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 58

This section explains procedures that must be performed before riding.

Operation 65

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

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

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 118

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 119

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 133

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

INTRODUCTION

Important Notes for Owners and Drivers

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

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

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

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

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

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

INTRODUCTION

Preservation of the Environment

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

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

Noise Level

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

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

Air Pollution

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

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

INTRODUCTION

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

Tunnel VIN (

Engine Serial Number (on recoil housing): _____________________________________

)(right side of tunnel): __________________________________________

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, on your vehicle or in this manual, indicates the potential for serious injury.

WARNING

A WARNING indicates a potential hazard that may result in serious injury or death.

CAUTION

A CAUTION indicates a potential hazard that may result in minor injury.

NOTICE

A NOTICE indicates a situation that may result in damage to the vehicle.

SAFETY

Operator Safety

Follow the recommended maintenance program beginning on page 79 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

WARNING

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

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

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

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

SAFETY

Operator Safety

Stay Clear of Track

Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation.

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, raise the hood, make the adjustment, secure shields and guards, secure the 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

051039

0006.31

Operator Safety

Riding Apparel

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 22.

WARNING

Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury.

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.

SAFETY

Operator Safety

Disabled Operators

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

Survival Preparation

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

For added protection, carry the following items on your snowmobile at all times:

• Spare Drive Belt • Winter Survival Kit

• Extra Set of Spark Plugs • Trail Map

• Tow Rope • Owner's Manual

• Extra Oil • First Aid Kit

• Fuel Deicer • Tool Kit

SAFETY

Operator Safety

Rider Capacity

Driving 1-Up - Some Polaris snowmobiles are designed for a single rider only. A decal on the console of these models indicates single rider operation.

Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only.

Machines designed for two riders should never be operated with more than two people on board. When traveling with a passenger, it's the driver's responsibility to operate the machine safely.

Slow down! Control becomes more difficult with two people on board. More space is required to make turns, and longer distances are necessary for stopping.

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 laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your machine travels. If your speed is 40 MPH, your machine is traveling about 60 feet per second. If you look back for only two seconds, your machine will travel about 120 feet. If your speed is 60 MPH, your machine will travel about 180 feet 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 machine to a stop in the distance illuminated by the headlight.

SAFETY

Operator Safety

Driver Awareness

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

Make sure the way is clear before crossing railroads and other roads and highways. The noise of your machine 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. Avoid travelling on frozen bodies of water.

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

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

Driving on Slippery Surfaces

WARNING

Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution.

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

SAFETY

Operator Safety

Driving Downhill

When riding downhill, shift your weight to the rear of the machine 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 machine 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.

SAFETY

Operator Safety

Driving in Hilly Terrain

WARNING

Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, 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 machine 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 machine 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 machine, pull the rear of the snowmobile around and point the front end and skis downhill. Remount the machine, 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. Operation of the engine with the belt removed may result in injury or damage to the engine.

Intake Silencer

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

Damage to the engine may occur if the intake silencer or filter are removed.

Clutches

Do not attempt to service the clutches.

All clutch service 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 machine into motion, but always operate within safety limits.

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 machines designed to carry a load.

SAFETY

Operator Safety

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

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 machine becomes stuck in snow, clear the running board area of snow, then step down the snow in front of the machine 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.

WARNING

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

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

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

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

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

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

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

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WINDCHILL CHART (_F)

Wind

Speed

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

MPH

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

5 3631251913 7 1 -5-11-16

10 34 27 21 15 9 3 -4 -10 -16

15 32 25 19 13 6 0 -7 -13

20 30 24 17 11 4 -2 -9 -15

25 29 23 16 9 3 -4 -11 -17

30 28 22 15 8 1 -5 -12

35 28 21 14 7 0 -7 -14

40 27 20 13 6 -1 -8 -15

45 26 19 12 5 -2 -9 -16

50 26 19 12 4 -3 -10 -17

55 25 18 11 4 -3 -11

60 25 17 10 3 -4 -11

Frostbite in >>

Actual Thermometer Reading (_F)

Equivalent Temperature (_F)

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

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

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

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

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

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

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

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

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

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

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

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

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

30 min. 10 min. 5 min.

WINDCHILL CHART (_C)

Wind

Speed

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

KPH

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

8 3 0 -4 -7 -11 -14 -18 -22 -25 -29

16 2 -2 -6 -10 -13 -17 -21 -24 -28

24 1 -3 -7 -11 -15 -19 -22 -26

32 0 -4 -8 -12 -16 -20 -24 -28

40 -1 -5 -9 -13 -17 -21 -25 -29

48 -1 -5 -9 -13 -18 -22 -26

56 -2 -6 -10 -14 -18 -22 -26

64 -2 -6 -10 -15 -19 -23 -27

72 -2 -7 -11 -15 -19 -23 -28

80 -3 -7 -11 -15 -20 -24 -28

88 -3 -7 -12 -16 -20 -24

96 -3 -8 -12 -16 -21 -25

Frostbite in >>

Actual Thermometer Reading (_C)

Equivalent Temperature (_C)

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

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

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

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

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

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

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

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

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

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

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

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

30 min. 10 min. 5 min.

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

SAFETY

Safety Decals and Locations

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

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

Clutch Cover Warning

This warning decal is found under the hood on the clutch cover:

WARNING Do not operate engine with hood open. Do not attempt adjustment with engine running. Do not operate engine with plenum/belt guard removed. Never run engine with drive belt removed. Never service clutches yourself -- see your dealer.

Pressure Cap Warning

This warning decal is found under the hood on the pressure cap of applicable liquid cooled models:

Do not open hot. Test or replace when changing coolant. Press down and turn to release cap. 13 PSI

SAFETY

“No Passenger”

Warning

“One Passenger”

Warning

Track Warning

Hot Surface Warning

Safety Decals and Locations

“No Passenger” Warning

Snowmobiles designed for a single rider only have the NO PASSENGER warning decal on the lower left side of the console:

WARNING This vehicle is designed for operator

only. NO PASSENGER

“One Passenger” Warning

Snowmobiles designed for an operator and one passenger have the ONE PASSENGER warning decal below the steering post:

WARNING This vehicle is designed for operator

and ONE passenger only.

For more information about operating with a passenger, see page 13.

Hot Surface Warning

The hot surface warning is located near the rear of the tunnel:

WARNING HOT SURFACE - DO NOT TOUCH Burn may result. Entire top of tunnel

may be hot. Install only accessories specifically

approved for this model by Polaris.

Track Warning

The track warning decal is at the rear of the tunnel:

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.

SAFETY

Reverse Warning

Operation

Warning

Safety Decals and Locations

Reverse Warning

The reverse warning decal is located on the console, either beside the steering post or below the windshield:

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

• Push button again to return to forward.

Operation Warning

The operation warning decal is also located on the console. See page 26 for the text.

SAFETY

Safety Decals and Locations

Operation Warning

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Not all models are equipped with all features shown.

1. Nosepan

2. Skis

3. Front Bumper (do not use for pulling or dragging the snowmobile)

4. Hood

5. Headlight

6. Windshield

7. Handlebar

8. Operator Seat

9. Taillight

10. Rear Bumper

11. Snow Flap

12. Suspension

13. Track

FEATURES

89 10

Not all models are equipped with all features shown.

1. Fuel Filler Cap

2. Ignition Switch

3. MFD Gauge

4. Engine Stop Switch

5. Throttle Control

6. Recoil Starter Handle

7. Hood Hold Down Straps

8. Parking Brake Lock

9. Handlebar Grip Warmer Switch

10. Thumbwarmer Switch

11. Electronic Reverse Button

12. Multi-Function Display (MFD) Control

13. Headlight Dimmer Switch

14. Brake Lever

FEATURES

Cargo Area

The maximum weight capacity for the cargo area is 15 lbs. (7 kg). Install only accessories specifically approved for this model by Polaris. Always secure cargo before operating. Do not exceed the cargo area weight limit.

Adjustable Headlights

Adjust the headlight beam by moving the adjuster to the left or right.

Detonation Elimination Technology (DET)

The DET system prevents damage to the engine from detonation by automatically reducing the engine timing and adding fuel whenever the sensors detect detonation.

You may notice decreased engine RPM and performance when DET is activated, but in most cases DET activation is temporary, and the timing will return to normal automatically. In extreme conditions the DET system retards timing and holds it in a retarded state. If this occurs, replace the fuel with recommended fuel or see your Polaris dealer for service.

Cause of DET Activation Solution

Poor quality fuel Replace with higher quality fuel Improper engine modifications Do not modify the engine

Sensor Fail-Safe

The DET includes a sensor fail-safe system to prevent the engine from damage if the sensor fails, becomes disconnected or is unable to detect detonation. The rider will experience a loss of power. The sensor must be reconnected or repaired to regain full power. See your Polaris dealer for service if this occurs.

TIP: The check engine light will flash six times if the sensor fails or becomes dis-

connected.

FEATURES

Instrumentation

MFD Component Identification

Item

1 Analog (if equipped)

2 Digital Gauge

3 CHECK ENGINE

Indicator (carb models)

4 Low Oil Indicator

5 High Temp Indicator

6 Brake Indicator

7 Reverse Indicator

8 High Beam Indicator

Digital Display Identification

Item

1 RPM or Speed

Altitude (if equipped) Service Interval

2 Electrical System

Voltage Level

3 MAX - Maximum MPH/

4 Air Temp (if equipped)

5Miles

6Hours

7 Fuel Level (if equipped)

KPH or RPM MPH -Miles per hour KPH - Kilometers per hour RPM -Engine crankshaft

revolutions per

minute

Engine Temp Degrees Celsius Degrees Fahrenheit

Kilometers

Tri p 1/ Tr ip 2 / Tri p F Service Label Altitude Label

FEATURES

Instrumentation

MFD Settings

With the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch (+) has a MODE button (top) and a SET button (bottom).

Standard vs. Metric

The MFD will display either standard or metric units of measurement. While viewing a screen that displays measurements (MPH, KPH or temperatures), press and hold the MODE switch until the unit of measurement changes (about 10 seconds).

Speedometer/Tachometer

The speedometer and tachometer can be viewed in either the analog or the digital display. If the analog display is set to show speedometer readings, the digital screen will automatically display the tachometer (option

1). If the analog is set to show the tachometer, the digital screen will show the speedometer (option 2).

To change preferences, press and hold the MODE button for three seconds. When the button is released, the new setting becomes active and screen colors change. See table below.

Option

1 Speed RPM Blue “mph” Blue

2 RPM Speed Red

Analog

Display

Digital

Display

Analog Screen

“X100rpm”

Digital

Screen

Backlight

Red

Backlight

FEATURES

Instrumentation

MFD Digital Display Programs

Press the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program will remain in the display until another is selected.

TIP: The analog will always display either MPH or engine RPM (whichever set-

ting is selected) regardless of the display program being viewed.

Performance Program

The Performance Program automatically displays either speed or tachometer, whichever is opposite the analog display. See page 31. It also displays electrical system voltage and fuel level (if equipped).

While in the Performance mode, press the SET button to cycle through the odometer, Trip 1, Trip 2, Trip F (if equipped with electronic fuel gauge) and Clock settings.

Instrumentation

MFD Digital Display Programs

Trip Settings

Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled.

1. To reset a trip odometer to zero, enter the Trip 1 or Trip 2 display.

2. Press and hold the SET button for

two seconds.

If the snowmobile is equipped with an electronic fuel gauge, Trip F automatically displays when the fuel level is low. The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1/8th tank. The Trip F odometer records distance traveled until enough fuel is added to raise the level above 1/4 tank. The fuel symbol and the fuel bar will continue to blink until the fuel level is above 1/4 tank. The Trip F odometer will automatically reset to zero after refueling.

FEATURES

Odometer Setting

The odometer records the vehicle's total distance traveled since manufacture. The odometer cannot be reset.

FEATURES

Instrumentation

MFD Digital Display Programs

Performance Program

Clock Setting

1. While in the CLOCK display, press and hold the SET button for five seconds.

2. When the hour starts flashing press

the SET switch once to advance one hour, or press and hold the SET button to advance the hour once every 0.2 seconds.

3. Press the MODE button to save the hour and flash the minutes.

4. Set the minutes in the same manner.

5. When finished, press the MODE button to save the new setting. If

the MODE button is not pressed within ten seconds, the clock will automatically save the new entry.

FEATURES

Instrumentation

MFD Digital Display Programs

Engine Program

The Engine Program automatically displays the engine coolant temperature, engine hours, electrical system voltage level and fuel level (if equipped). On machines equipped with altimeter sensor and ambient air temperature sensors, altitude and ambient air temperature will display as additional screens in the engine program. Press the SET button to display the ambient air temperature and altitude screens.

Air Temperature (if equipped)

The MFD displays actual air temperature. Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement.

Hour Meter

The hour meter records the total hours of engine operation since manufacture. This meter cannot be reset.

Engine Temperature

A thermometer measures water temperature, giving an indication of engine temperature.

FEATURES

Instrumentation

MFD Digital Display Programs

Engine Program

Altitude (if equipped)

The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment.

TIP: Press and hold the MODE switch for ten sec-

onds to switch between standard and metric units of measurement. When "ALt" displays, the program is in the metric mode.

1. Enter the Engine Program and select the altimeter display.

2. Press and hold the SET button for five seconds.

3. When the digits begin to flash, press the SET button once to

advance 50 feet (15 m), or press and hold the button to advance 100 ft. (30 m) every 0.1 seconds. Adjust the altitude display to within 50 ft. (15 m) of current altitude.

TIP: The gauge reads barometric pressure and allows the rider to compensate

for daily fluctuations in air pressure. The gauge can adjust the displayed altitude to +/- 1300 ft. (396 m) from the preset value. It will adjust up to +1300 ft. (396 m) above the calibrated altitude. Once the +1300 ft. (396 m) offset has been reached, the next adjustment is -1300 ft. (396 m) from the calibrated altitude, and 50 ft. (15 m) will be added to the altitude each time the SET button is pressed.

4. Press the MODE button to hold the reading at the adjusted value. If

it's not pressed within five seconds, the gauge will automatically save the new setting.

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

The History Program automatically displays electrical system voltage level and fuel level (if equipped).

While in the History mode, press the SET button to view maximum vehicle speed, maximum engine rpm or the current service interval setting. The gauge automatically logs the maximum speed and engine rpm even if the History Program is not currently displayed.

The History Program will display the history of the Maximum Speed, Maximum RPM and Service Interval settings.

Maximum Speed/RPM Reset

While in either the MAX MPH or the MAX RPM mode, press and hold the SET button for three seconds to reset the recorded maximum values for both MPH and RPM. Both of these values are reset at the same time. Reset the MAX MPH/RPM values before each run to obtain accurate readings.

TIP: Due to electrical noise, the MFD may occa-

sionally display MAX MPH/RPM values that are not representative of actual values.

FEATURES

Instrumentation

MFD Digital Display Programs

Service Interval Reminder

The gauge logs the number of engine hours between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due. "SErVCE" will flash in the odometer area and "ENG" will flash in the icon area for five seconds each time the vehicle is started until the service reminder is reset.

To reset the reminder at the existing interval:

1. Enter the service interval screen.

2. Press and hold the SET button for ten seconds, continuing to hold

even after the display begins to flash.

3. When the display stops flashing, release the button. The service

interval has been reset.

To reset the reminder at a new interval:

1. Enter the service interval screen.

2. Press and hold the SET button for five seconds, until the hours

begin to flash.

3. Immediately release the button.

4. Press the button again up to five times to advance the reminder in

50-hour increments. The maximum interval is 250 hours.

To disable the service interval reminder, press the SET button once after reaching 250 hours on the display. The gauge will display "OFF".

FEATURES

Instrumentation

MFD Battery Replacement (models with clocks)

If the clock function of the MFD isn't working properly, replace the battery. Replacement batteries are available from your dealer.

1. Remove the plenum from the underside of the hood.

2. Locate the black battery compart-

ment. It has a red wire and a brown wire with a white stripe. It's located about three inches down the main harness from the point where the harness connects to the MFD.

3. Cut the plastic cable tie from the out-

side of the compartment.

4. Carefully cut the bottom of the com-

partment (opposite the wires) to separate the heat-sealed seams. Squeeze the corners of the compartment inward so the battery is visible.

TIP: Note the orientation of the battery before removing it. An incorrectly

installed battery will not maintain the clock.

5. Using needle-nose pliers, grasp the battery and rotate it so the lead-

ing edge of the battery is raised slightly away from the battery holder. Pull the battery out gently.

TIP: The battery will not come out of the holder unless the leading edge of the

battery is raised. Hold the battery compartment, not the wires, while removing the battery. Pulling on the wires will separate them from the battery holder.

FEATURES

Instrumentation

MFD Battery Replacement (models with clocks)

6. Install a new battery with fingers only.

7. Seal the end of the battery compartment using high strength doublesided tape between the two compartment halves or high strength single-sided tape around the outside of the compartment.

8. Make sure the taped seam of the compartment faces the downward side of the wire harness.

9. Install a cable tie to secure the compartment to the wire harness in the same location where the previous cable tie was located. Make sure the battery wires are not stretched tight.

Gauge Cleaning

1. Wipe the gauge face as needed using a clean cloth and a mild soap

and water solution. Wipe dry with clean, soft cloth.

2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution. Do not remove the electrical connectors or protective rubber boot. Do not spray the back side of the gauge or the wire harness with a pressure washer or other water source.

NOTICE: To prevent damage to the lens, do not use alcohol for cleaning. Do not

allow chemicals or sprays to come into contact with the lens. Immediately clean off any gasoline that splashes on the gauge during refueling.

THE PERFECT FIT

Front Suspension Adjustments

Independent Front Suspension (IFS)

Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments.

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 machine 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.

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. A-arms

IFS Adjustment Options

• Front shock spring preload

• Optional springs

• Optional shock valving

• Compression damping (SP models)

THE PERFECT FIT

Low

Preload

High

Preload

Front Suspension Adjustments

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.

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

Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension. Never exceed one inch of preload beyond the factory settings, and ensure that both sides are adjusted the same. When decreasing preload, make sure 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.

TIP: Not all models have shocks with thread-adjustable spring preload. See your

dealer for more information.

NOTICE: On some models equipped with a plastic adjuster nut, the nut will

break if it is unscrewed from the threaded body. Do not force the nut if resistance suddenly increases while you’re turning it.

THE PERFECT FIT

Softer

Stiffer

Front Suspension Adjustments

Shock Compression Damping (SP models)

Turn the adjuster to make adjustments to the compression damping. When adjusting, we recommend that you turn the adjuster only one click, then test ride. Always adjust both shocks equally.

The standard setting is 4 clicks from the softest position.

• Turn the adjuster to the left for a stiffer ride.

• Turn the adjuster to the right for a softer ride.

Shock Valving

Some shocks can be revalved if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. Please see your Polaris dealer.

WARNING

Changing shock valving requires special tools and a sound knowledge of mechanical theory, tool use, and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a 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.

• 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.

• 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 Suspension Maintenance beginning on page 114.

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 108.

THE PERFECT FIT

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

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

Take the first measurement with no rider and with the rear suspension at full extension. The rear bumper may need to be lifted upward slightly to fully extend the rear suspension.

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

THE PERFECT FIT

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

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

Suspension Recommended Sag Adjustment

IQ (121) 4-5 inches (10-13 cm) Torsion Spring

Preload

SwitchBack

(136)

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

preference and riding conditions.

4-5 inches (10-13 cm) Torsion Spring

Preload

See

Page

THE PERFECT FIT

Soft Medium Firm

Rear Suspension Adjustments

Torsion Spring Preload

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

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

THE PERFECT FIT

Upper

Nuts

Rear Suspension Adjustments

Limiter Strap Position (Ski Pressure)

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

SP models have only one limiter strap.

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

2. Relocate the straps to the desired position.

3. Reinstall the nuts and washers. Tighten securely.

THE PERFECT FIT

Stiffer Softer

Rear Suspension Adjustments

Rear Shock Compression Damping (Premium Shock) Front Track Shock Compression Damping (SP Models)

Turn the adjuster on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster one click, then test ride.

• Turn the adjuster clockwise for a stiffer ride.

• Turn the adjuster counterclockwise for a softer ride.

THE PERFECT FIT

Rear Suspension Adjustments

Suspension Coupling

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

Front To Rear Coupling and the Front Rear Scissor Stop (FRSS)

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

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

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

THE PERFECT FIT

Rear Suspension Adjustments

Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS)

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

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

Rear Rear Scissor Stop (RRSS) - Attributes

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

• Reduced weight transfer.

• Improved chatter bump ride.

• Improved cornering performance.

THE PERFECT FIT

HIGH

LOWLOW

MEDIUM

RRSS

FRSS

Rear Suspension Adjustments

Weight Transfer During Acceleration

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

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

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

TIP: Your dealer can help you with ini-

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

THE PERFECT FIT

Loosen top bolts to adjust handlebar angle

Loosen bottom bolts to adjust handlebar position

Handlebar Adjustments

Handlebar Position

1. Loosen the four bolts on the

bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver.

2. Adjust the handlebar forward

or rearward to the desired position.

3. Tighten the bolts.

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. Tighten the bolts.

THE PERFECT FIT

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.

THE PERFECT FIT

Traction Products

Studs

Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products.

Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products.

See your dealer about installing studs and/or carbides.

NOTICE: Always install wear strips before installing studs. Failure to install wear

strips may result in cooler or tunnel damage. See page 57. Never add shims to the wear strip. Track damage will result because

of lack of clearance between upper carrier wheels and track. Use of studs longer than the recommended length on machines

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

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

When studded tracks are used, increased wear to the brake pads will result from increased braking. Extended-wear brake pad kits are available. See your dealer.

NOTICE: Aggressive studding patterns may require grinding protruding stud

bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger

damage. The center of the stud must be at least 1 1/8 the outside edge of the track.

I (2.86 cm) from

THE PERFECT FIT

Traction Products

nCarbide 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 113.

If your machine 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.

Wear Strips

To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. 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 heat exchangers. Lack of clearance may result in damage to heat exchangers.

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. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items.

Item See Page

Drive Belt Condition 102

Steering System 62

Recoil Rope 63

Coolant Level 91

Parking Brake Lock/Brake Lever/Brake System 60, 61, 96

Auxiliary Shut-Off Switch (Engine Stop Switch) 64

Ignition Switch 64

Taillight/Brakelight/Headlight 64

Suspension Mounting Bolts 114

Skags (Wear Bars) 113

Ski Saddle and Spindle Bolts 114

Hood Straps/Latches 63

Seat Latches (if equipped) 63

Throttle Lever/Safety Switch 72, 73

Rear Wheel Idler Bolts 109

Tether Switch/Strap (if equipped) 64

Track Alignment/Condition 62, 110

Rail Slide Condition 114

Chaincase Oil Level 85

Injection Oil Level 71

PRE-RIDE INSPECTIONS

Before Starting the Engine

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

WARNING

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

Read and Understand Your Owner's Manual

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

n 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.

n Throttle Safety Switch

Test the throttle safety switch system before the machine is operated. See page 72.

PRE-RIDE INSPECTIONS

1/2I (1.3 cm)

Before Starting the Engine

n 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 1/2I (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 98 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 97.

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

n Parking Brake Lever Lock

Use the parking brake lever lock only when you want the machine 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 Reser-

voir/ Cover

4. Fluid Level Indicator

Lock Engagement

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

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

Lock Release

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

WARNING

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

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Steering System

WARNING

Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice.

n Track

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.

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

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

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Hood Latches

The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmobile.

n Seat Latches

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

n 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

Start the Engine and Check

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Before Starting the Engine beginning on page 59.

n 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.

n Ignition Switch

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

n Tether Switch (if equipped)

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

n Lighting

Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating.

n Mirrors (if equipped)

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

n Operating Area

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

OPERATION

Starting the Engine

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

1. Turn the key to the ON position.

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

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

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

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

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

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

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

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

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

snap back into the housing. Damage may result.

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

CAUTION

Restarting an Engine

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

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

2. Turn the key to the OFF position.

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

open position.

4. Crank the engine several times to clear the engine.

5. Release the throttle.

6. Restart the engine using the normal starting procedure.

OPERATION

Engine Break-In

No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of fuel with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

NOTICE: 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 machine speeds to reduce friction on all close-fitting machined parts, allowing them to break in slowly without damage.

Use of any lubricants other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris lubricants for your vehicle.

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

OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil tank when refueling. See page 71.

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

Oil Recommendations

This snowmobile is equipped with a variable exhaust system (VES). Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends the use of VES II 2 Cycle Oil for this engine. See page 118 for the part numbers of Polaris products.

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

Slide Rail and Track Cooling

NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide

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

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

Track Warm-Up

WARNING

A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine 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 sup-

port the rear of the snowmobile at the rear bumper. The track should be about 4I (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 suffi-

ciently during colder outdoor temperatures.

4. Release the throttle, apply the brakes, shut

off the engine and lower the machine to the ground.

5. Grasp the skis by their front loops and move them from side to side

to loosen snow and ice.

OPERATION

Fuel

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

• Always turn off the engine before refueling.

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

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

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

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

WARNING

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

OPERATION

Fuel

For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol

(including E85).

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

Fuel System Deicers

If you use non-oxygenated fuel, 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 engine damage resulting from fuel system icing and lean fuel mixtures. Never use deicers or additives containing methanol. Polaris also recommends the use of Carbon Clean Plus. See page 118 for the part numbers of Polaris products.

If you use oxygenated fuel containing ethanol, additional alcohol deicers or water absorbing additives should not be used.

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

Always protect painted surfaces when handling fuel.

OPERATION

n Oil

Low Oil Indicator Light

The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 67 for oil recommendations.

Low Oil Level

Maintaining the proper oil level will prevent system aeration and possible loss of pumping action, which could result in engine damage. This is especially important when the machine is operated in mountainous terrain.

NOTICE: Operating the snowmobile without adequate engine lubrication can

Always maintain a visible level of oil in the tank. If oil is not visible, continued operation may cause serious engine damage. See page 67 for oil recommendations.

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

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

OPERATION

n 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.

n 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 safety switch can result in serious injury or death in the event of an accident. If the throttle safety switch does not shut off the engine during a carburetor/throttle system malfunction, immediately push down the engine stop switch. Do not start the engine again until the malfunction has been corrected by your dealer.

Test the throttle safety switch system daily before operation.

1. Sit on the seat.

2. Start the engine and allow it to idle.

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

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

OPERATION

Throttle Lever

WARNING

An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine.

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

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor/throttle body to determine what caused the safety switch to activate.

3. Test the throttle lever by compressing and releasing it several times. The lever and cable must return to the idle position quickly and completely.

4. If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures.

5. If the engine doesn't start, 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 machine 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 machine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealer for service as soon as possible.

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 72 for more information about the engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES

Ignition Switch Interrupts ignition circuit

Brake Slows jackshaft

Engine Stop Switch Interrupts ignition circuit

Throttle Safety Switch Interrupts ignition circuit

Tether Switch (Option) Interrupts ignition circuit

OPERATION

Electronic Reverse (PERCt)

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

WARNING

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

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

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

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

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

OPERATION

Electronic Reverse (PERCt)

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

3. Push the yellow reverse button on the left-hand control for one second, then release. The engine will automatically reduce RPM and start a reverse rotation. A flashing reverse light on the instrument panel will indicate that the transmission is in reverse.

4. Apply the throttle slowly to make sure the transmission is in reverse.The maximum engine RPM will be 6000 when in reverse.

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

restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

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

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.

ward.

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 4I (10 cm) off the ground.

Remove the key and cover the machine.

To w i n g

Do not use the front bumper to pull or drag the snowmobile. The front bumper is not designed for this type of use and may detach from the vehicle if force is applied.

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.

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.

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 133.

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

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

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

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

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

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

MAINTENANCE

Periodic Maintenance Interval Table

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

Item See

Clutch Alignment Offset (without belt)

Drive Belt Condition 102 II II

Clutches 101 CCC

Belt Tension -- II II

Clutch Sheaves 101 II II

Engine Mounts -- II II

Recoil Rope -- II II

Engine Torque Stop 105 II II

Cylinder Head Bolts -- II I

Cylinder Base Nuts -- II I I

Ignition Timing BTDC -- II I

VES System -- CC C I

Coolant Level 91 IIRI

Coolant Hose -- II II

Heat Exchangers 93 II I I I

Coolant Circulation -- II I

Coolant Leaks -- II II

Spark Plug Condition 88 II IRI

Exhaust Pipe 94 II

Exhaust Retaining Springs

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

Page

150 mi.

(240 km)

101 II I

ENGINE/COOLING

94 II II

(800 km)

CLUTCH

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Hose Routing -- II II

Hose Condition -- IIII

Fluid Leaks -- IIII

Brake Pads 96 II II

Brake Disc -- IIII

Parking Brakes 61 II II

Brake System 60, 96 I

Brake Fluid 97 R

Idle RPM -- II I

Throttle Lever 73 II I I I

Oil Pump Lever (synchronize)

Throttle Cable 84 LLL

Throttle Position Sensor

Fuel Lines 90 II I I I

Fuel Filter 90 RR

Oil Filter 89 RR

Oil Lines 89 III

Air Box -- II I II

Auxiliary Shut-Off Switch

Throttle Safety Switch 72 II I I I

Ignition Switch -- II I I I

Taillight 64 II I I I

Brakelight 64 II I I I

Headlight 64 II I I I

Page

150 mi.

(240 km)

FUEL MANAGEMENT

-- II I

ELECTRICAL

64 II I I I

(800 km)

BRAKES

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Ski Toe Alignment -- II I

Suspension Mounting Bolts

Steering Fasteners -- II I IC

Rear Suspension Fasteners

Suspension Shock Oil -- II II

Cooling Fins and Shroud

Drive Shaft Bearing 84 LL L I

Jackshaft Bearings 116 LL L I

Skags (Wear Bars) 113 II I II

Ski Saddle/Spindle Bolts

Drive Chain Tension 95 II I I I

Hood Latches 63 II I I I

Rear Wheel Idler Bolts 109 II I I I

Idler Bolt Jam Nut 109 II I I I

Rear Suspension Pivot Shafts

Steering Post U-Joint 83 LL L

Camber Alignment -- II I

Handlebar Centering -- I

Tether Switch and Strap 64 II I I I

Track Alignment 110 II I I I

Track Tension 108 III II

Front Limiter Strap -- II I I I

Rail Slide Condition 114 I

Chaincase Oil 85 II IRI

Page

150 mi.

(240 km)

-- II I I I

-- II II

-- II I I I

83 LL L

500 mi.

(800 km)

CHASSIS

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

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

MAINTENANCE

IQ 121 Shown

The Dragon SP rear suspension

has no grease points, it does

not require lubrication.

Lubrication

Rear Suspension

Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 79 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.

IQ 121/Switchback 136 Rear Suspension

MAINTENANCE

Lubrication

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.

Throttle Cable

Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown.

Lubrication

n Chaincase Oil

Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 79. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). Change the chaincase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally.

Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 118 for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on a level surface.

2. View the oil level at the sight glass.

3. Remove the fill plug (3) and add the

recommended oil as needed. Do not overfill.

4. Reinstall the fill plug, making sure it

is seated properly.

MAINTENANCE

Lubrication

Chaincase Oil

Oil Change

1. Position the vehicle on a level surface.

2. Remove the drain plug (4) and drain the oil into a drain pan. Allow the oil to drain completely.

3. Clean off all metal shavings from the plug.

4. Install a new sealing washer on the drain plug. The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.

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

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

7. Add 11 oz. (325 ml) of the recommended oil. Do not overfill.

8. Reinstall the fill plug, making sure it is seated properly.

MAINTENANCE

Spark Plugs

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

Refer to your Owner's Manual Supplement for the specific spark plug to be used in your machine.

Change the spark plugs every 2000-2500 miles (3200-4000 km).

• 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.

NOTICE: Using non-recommended spark plugs can result in serious engine

damage. A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile. See your Owner’s Manual Supplement.

MAINTENANCE

Spark Plug Condition

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.

CAUTION

A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.

Normal

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

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

MAINTENANCE

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation.

4. Torque to 18-22 ft. lbs. (24-30 Nm).

5. Reinstall the spark plug cap.

Oil Lines

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

Oil Filter

The oil filter is located at the side of the oil tank. Have your dealer change the oil filter and bleed the system annually or every 1000 miles (1600 km).

TIP: The direction of the arrows indicates

the direction of flow through the filter.

MAINTENANCE

Intake Filters

The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow.

NOTICE: Operating the

Fuel Pump

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

Fuel Filter/Fuel Lines

See your Polaris dealer for replacement of the fuel filter every 1000 miles (or annually).

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

NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel

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

lines may cause damage to the lines. If a fuel line has been damaged or kinked, replace it promptly.

MAINTENANCE

Cooling System

Coolant

The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or operated at extremely low temperatures, greater protection may be required. Please see your Polaris dealer.

When adding or changing coolant, Polaris recommends using Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture. See page 118 for Polaris products.

Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.

n Coolant Level

The engine coolant level is controlled by the recovery system. The recovery system components are:

• Coolant bottle or overflow tank

• Engine filler neck

• Pressure cap

• Connecting hoses

Always maintain the coolant level between the minimum and maximum marks on the coolant bottle (when engine is cold) to prevent overheating and serious engine damage.

NOTICE: Operating the snowmobile with insufficient coolant will result in over-

heating and serious engine damage. Always maintain the coolant level as recommended.

MAINTENANCE

Cooling System

Coolant High Temperature Indicator Light

CAUTION

Steam and hot liquids will cause burns to your skin. Never remove the pressure cap when the engine is warm or hot.

The high temperature indicator light will illuminate when engine coolant temperature becomes too hot for safe continued operation of the engine. If you must drive your machine after the high temperature indicator light has come on, drive slowly and stop frequently to allow the engine to cool down. Driving in deep snow will also help cool the engine. See your dealer for service.

Add coolant if the level is low. Engine performance will be reduced if you continue operating when the high temperature light is on.

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine, drain the system completely every two years and add a fresh mixture of antifreeze and distilled water. This service must be performed when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile.

MAINTENANCE

Cooling System

Bleeding the Cooling System

CAUTION

Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot.

Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part.

NOTICE: If coolant flow becomes restricted or plugged, coolant loss, air lock or

Perform the bleeding procedure when the engine is cold.

1. Position the vehicle so that the top of the tunnel is level. Elevate the

2. Remove the pressure cap and fill the coolant bottle with properly

3. Remove the bleed screw from the water outlet manifold and/or the

4. Add coolant to the coolant bottle to the maximum mark.

5. Start the engine and run at a fast idle for two to three minutes.

6. Stop the engine and check the coolant bottle level. Fill as required.

7. Feel the heat exchangers under the running boards. (On Switchback

8. Replace the pressure cap and carefully lower the front end of the

engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced.

front of the vehicle slightly if necessary.

mixed coolant to the maximum mark.

thermostat housing. Allow the coolant to bleed through the system until it runs out the bleed holes. Reinstall the bleed screw into the manifold.

Loosen the bleed screw occasionally to purge any trapped air.

models, feel the tunnel gripper coolers on both sides.) If the system is bled properly, they'll be warm to the touch. If they're not, repeat step 5. Lift the front of the machine slightly to assist in the bleeding.

machine.

MAINTENANCE

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 hood and inspect the muffler and pipes for cracks or damage.

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

grommets.

3. Check for loose clamps on the pipe covers.

Drive Chain Tension

Check drive chain tension weekly and before each long trip. To obtain correct chain tension:

1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.

2. Loosen the adjuster bolt jam nut (1).

3. Finger tighten the adjuster bolt (2)

until it can no longer be adjusted by hand, then back off 1/4 turn.

4. Tighten the jam nut while holding

the adjuster bolt. Torque to 21 ft. lbs. (28 Nm).

5. Release the brake lever lock.

MAINTENANCE

Brakes

Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See page 60.

Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16I). 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

Brake Components

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material (Replace when thickness is less than 1/16I/1.5 mm).

I).

Excessive Lever Travel

Hydraulic brakes are selfadjusting, but if excessive brake pad clearance develops, bring the machine 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 118 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 decals, paint and some plastics. Always wipe

up spills immediately.

Polaris 600 Dragon SP, 800 Dragon SP, IQ Shift 136 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual