Polaris 600 HO IQ, 600 HO Switchback User Manual

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone [phone] Fax [phone]
Part No. 9920459 Rev 02
Printed in USA

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!

1

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

RIDER SELECT is a trademark of Polaris Industries Inc.

Copyright 2005 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.
2007 600 HO IQ/600 HO SwitchBack Owner's Manual P/N 9920459

2

TABLE OF CONTENTS

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

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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

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

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 40

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 122

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 123

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 138

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

3

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.

9

Vehicle Model Number: ___________________________________________________

Tunnel VIN (

Engine Serial Number (on recoil housing): ____________________________________

Key Number: ___________________________________________________________

9)(lower right side of the tunnel): _________________________________

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.

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.

4

INTRODUCTION

Preservation of the Environment

Polaris is committed to supporting an environmental education cam­paign. We encourage governments 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.

5

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, alerts you to the
potential for injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious
injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor
injury or damage to the vehicle.

CAUTION

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

NOTE

A note will alert you to important information or instructions.

6

SAFETY

Operator Safety

Follow the recommended maintenance program beginning on page 82
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.

7

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.

8

SAFETY

Operator Safety

Riding Position

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

WARNING

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

Riding Apparel

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 20.

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.

4

E

051039

0006.31

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.

9

SAFETY

Operator Safety

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

10

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.

Rider Capacity

Your Polaris snowmobile is designed for a single rider only. Do not
carry a passenger.

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.

11

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.

RR

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.

12

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 either the
American Avalanche Association online at www.americanavalancheas­sociation.org or the U.S. Forest Service National Avalanche Center at
www.avalanche.org.

13

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.

NOTE: If your snowmobile is equipped with RIDER SELECT, perform

this check in both the full up and full down steering positions.

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.

14

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.

15

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.

16

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.

17

SAFETY

Operator Safety

Inadequate Snow Conditions

WARNING

Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could
cause irreversible track damage and lead to serious injury.

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 machine. Driving in too lit­tle snow will result in excessive wear and damage to the slide rail, track
and/or engine.

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.

CAUTION

When operating on icy surfaces or hard-packed snow, avoid overheating the
slide rail and track. Lack of lubrication and cooling will cause overheating of
the slide rail and track, resulting in premature wear and failure. If frequently
operating in low cooling conditions, see your dealer for an optional wheel kit
that will reduce the wear from overheating.

18

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 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. Jumping may injure your back
because of spinal compression. 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.

19

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

in

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

in

KPH

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

8 3 0 - -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 >>

20

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

21

SAFETY

Safety Decals and Locations

Track Warning

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

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.

"No Passenger" Warning

The "NO PASSENGER" warning
decal is on the console below the
steering post:

WARNING

This vehicle is designed for
operator only.

“NO PASSENGER”

9

9

22

SAFETY

Safety Decals and Locations

Reverse Warning

The reverse warning decal is located
on the console 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
located on the lower console. See
page 24 for the text.

9

9

23

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.

24

FEATURES

6

3

4

5

7

8

2

1

15

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Seat

6. Seat Storage Compartment

7. Taillights

8. Rear Bumper

9. Snow Flap

10. Suspension

11. Track

12. Console Storage Compartment (if equipped)

13. Skis

14. Nosepan

15. Front Bumper

14

13

9

10

11

12

25

FEATURES

4

3

5

6

7

8

9

2

1

1. Fuel Filler Cap

2. RIDER SELECT (if equipped)

3. Ignition Switch

4. Brake Lever

5. Headlight Adjuster

6. MFD Gauge

7. Engine Stop Switch

8. Throttle Control

9. Hood Hold Down Straps

10. Recoil Starter Handle

11. Choke Lever

12. Parking Brake

13. Handlebar Grip Warmer Switch

14. Thumbwarmer Switch

15. Electronic Reverse Button

16. Multi Function Display (MFD) Control

17. Headlight Dimmer Switch

12

17

13

11

14

10

15

16

26

FEATURES

RIDER SELECT Adjustable Steering System

The RIDER SELECT adjustable steering system (if equipped) allows
you to adjust the handlebar position to fit your style of riding.

Setting Position Riding Style

Comfort 1, 2 Pull the system rearward to one of the first two

Control 3, 4, 5 Move the system to one of the middle three posi-

Attack 6, 7 Push the system forward to one of the last two

Some aftermarket accessories (including windshields and cargo bags) may
interfere with the handlebar. Such accessories could limit your ability to steer
the vehicle and/or may contact the brake lever. This could lead to loss of
control resulting in serious injury or death. Always be sure that accessories
do not contact the handlebar or brake lever at any steering position and at
any RIDER SELECT position.

positions for all-day trail riding comfort.

tions for improved handling and cornering on the
trails.

positions for easy sitting-to-standing transitions and
maximum agility in rugged terrain.

WARNING

27

FEATURES

RIDER SELECT Adjustable Steering System

WARNING

Attempting to adjust the handlebar position while the snowmobile is moving
could result in loss of control and serious injury or death. Always stop the
snowmobile before attempting to adjust the steering system.

1. Stop the snowmobile.

2. Press the release button and
move the handlebar forward
or rearward to the desired
position.

WARNING

Do not lubricate the RIDER SELECT mechanism. Doing so could cause loss
of control and result in serious injury or death. The RIDER SELECT mecha­nism is lubricated for life at the factory.

Cargo Rack

If equipped, the maximum weight
capacity for the cargo rack is 15
lbs. (7 kg). Always secure cargo
before operating. Do not exceed
the rack weight limit. Do not
allow a passenger to sit on the
seat back or the cargo rack.

28

9

Fuel Valve

The fuel valve is located under the
hood. Turn the fuel valve off when­ever the snowmobile is stored or
parked.

1. Turn the valve clockwise to turn
off the fuel supply.

2. Turn the valve counter-clock-

wise to turn on the fuel supply.

Seat Storage Compartment

Open or close the stor­age compartments
with the key, or lift the
seat lever and lift the
seat to access the
under-seat storage
area.

Adjustable Headlights

FEATURES

ON OFF

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

Radiator Compartment
Access Panel

The access panel is provided for
cleaning debris from the radiator.

29

FEATURES

Detonation Elimination Technology (D.E.T.)

The DET system prevents damage to the engine from detonation while
developing the maximum power of the engine safely. A detonation sen­sor monitors the engine and responds to detonation by automatically
reducing the engine timing. This can result in decreased engine RPM
and performance.

The engine is designed to provide maximum power when premium (91
octane) fuel is used. If a lower octane fuel is used, or if the jetting is
incorrect for your altitude, the DET system will retard ignition to pre­vent detonation.

When the DET system is adjusting the timing, the CHECK ENGINE
light will flash. In most cases the flashing will be temporary and the
timing will return to normal. If there is intermittent flashing, it’s likely
that the fuel or jetting is incorrect.

In extreme conditions the DET system retards timing and holds it in a
retarded state. The CHECK ENGINE light will remain on until the
engine is turned off and restarted.

30

FEATURES

Detonation Elimination Technology (D.E.T.)

DET Troubleshooting

Use this chart to determine causes and solutions for detonation. If none
of these conditions exists and the sensor remains activated, see your
Polaris dealer for diagnosis.

Possible Cause Solution

Poor quality fuel Replace with higher quality fuel
Improper engine modifications Do not modify the engine
Incorrect jetting Use the correct jetting for your altitude

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 in power. The sensor must
be reconnected or repaired to regain full power.

NOTE: The CHECK ENGINE light will flash six times if the sensor fails

or becomes disconnected.

31

FEATURES

Instrumentation

MFD Component Identification

Item

1 Analog Gauge (if equipped)

2 Digital Gauge

3 CHECK ENGINE Indicator

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/

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

revolutions per

minute

1

3

4

1

2

8

5

7

6

2

4 Air Temp (if equipped)

Engine Temp
Degrees Celsius
Degrees Fahrenheit

5Miles

Kilometers

6Hours

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

7 Fuel Level (if equipped)

32

5

4

6

7

3

Instrumentation

MFD Settings

With the engine running, use the
MFD Control Switch to set the MFD
display to your preference. The
rocker switch (9) has a MODE but­ton (top) and a SET button (bottom).

FEATURES

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 the digital display.
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.

Digital Display Screen Backlight

RPM Blue

Speed Red

9

33

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.

Performance Program

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

34

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.

35

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.

36

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.

NOTE: Press and hold the MODE switch for

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

NOTE: The gauge reads barometric pressure and allows the rider to

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

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

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.

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.

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

37

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

The History Program automatically displays electrical system voltage
level and fuel level.

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.

NOTE: Due to electrical noise, the MFD

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

38

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.

NOTE: 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".

39

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 (if
equipped)

1

2

3

4

40

THE PERFECT FIT

Front Suspension Adjustments

Shock Spring Preload

The factory preload setting should be appropriate for most riders and
conditions. Please see your Polaris dealer for assistance before attempt­ing to adjust preload.

Increasing the spring preload too much may adversely affect the han­dling of the snowmobile and the performance of the rear suspension.

Decreasing the spring preload too much may allow the spring retainer to
fall off.

The springs can be changed if spring preload alone isn't sufficient and
further adjustment is desired to control suspension stiffness. See your
Polaris dealer for more information.

Shock Valving

Shocks can be revalved if spring preload alone isn't sufficient and fur­ther adjustment is desired to control suspension stiffness.

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.

41

THE PERFECT FIT

Front Suspension Adjustments

Shock Compression Damping (if equipped)

Turn the adjustment knob to make
adjustments to the compression damp­ing. The standard setting is 10 clicks
from the full stop position. When
adjusting, we recommend that you turn
the knob only one click, then test ride.
Always adjust both shocks equally.

• Turn the knob clockwise (A) for a
stiffer ride.

• Turn the knob counter clockwise (B)
for a softer ride.

A

B

42

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.

43

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.

NOTE: 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 118.

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 110.

44

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.

NOTE: 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.

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.

X

Y

Suspension Recommended Sag Adjustment

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

SwitchBack

(144)

5 inches (13 cm)
(see note below)

Preload

Torsion Spring

Preload

See

Page

46

51

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

45

THE PERFECT FIT

IQ 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.

Soft Medium Firm

46

THE PERFECT FIT

IQ Rear Suspension Adjustments

Rear Shock Compression Damping (Premium Shocks)

Turn the adjustment knob on the shock
reservoir to make adjustments to the

AB

compression damping. Positions are
labeled on the shock. When adjusting,
we recommend that you turn the
adjuster slightly, then test ride.

•Turn the knob clockwise (A) for a
stiffer ride.

•Turn the knob counter clockwise (B)
for a softer ride.

47

THE PERFECT FIT

IQ 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.

48

THE PERFECT FIT

IQ 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.

49

THE PERFECT FIT

IQ 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.

NOTE: Your dealer can help you

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

HIGH

LOWLOW

MEDIUM

50

THE PERFECT FIT

SwitchBack Rear Suspension Adjustments

Torsion Spring Preload

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

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

Soft (long end of cam to front)

Medium (short end of cam up)

Firm (long end of cam up)

Soft Medium Firm

Limiter Strap Position

High: Limiter strap in high position
increases ski pressure

Low: Limiter strap in low position
decreases ski pressure

High

Low

51

THE PERFECT FIT

SwitchBack Rear Suspension Adjustments

Rear Shock Compression Damping

Turn the adjustment knob 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 slightly, then test ride.

• Turn the knob clockwise (A) for a
stiffer ride.

• Turn the knob counter clockwise (B)
for a softer ride.

AB

52

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.

53

THE PERFECT FIT

Handlebar Adjustments

When making handlebar adjustments, always be sure the handlebars,
brake lever and throttle lever operate smoothly and do not contact the
fuel tank, windshield or any other part of the vehicle when the handle­bars are turned fully to the left or right.

Handlebar Angle

Follow these steps to adjust handle­bar angle at the handlebar block.

1

1. Remove the handlebar cover (1).

2. RIDER SELECT models:

Using a 7/16I wrench, loosen
the four nuts (2) on the bottom
of the adjuster block. Turn the
handlebar left or right to access
the rear nuts.

3. Loosen the four upper adjuster

block bolts (3).

4. Adjust the handlebar to the

desired angle.

5. Torque the front bolts first, then

torque the rear bolts. Torque the
bolts to 11-13 ft. lbs. (15-18
Nm).

6. Reinstall the handlebar cover.

3

2

RIDER SELECT
Steering Post

1

3

Stationary
Steering Post

4

54

THE PERFECT FIT

Handlebar Adjustments

Handlebar Position

If your snowmobile is equipped with the RIDER SELECT feature,
adjust handlebar position as outlined on page 27. For models with sta­tionary steering posts, adjust handlebar position as outlined below.
Refer to the illustration on page 54.

1. Remove the handlebar cover.

2. Loosen the four upper (3) and four lower (4) adjuster block bolts.

3. Adjust handlebar position.

4. Torque the bolts to 15-17 ft. lbs. (20-23 Nm). Torque the front bolts

first.

5. Reinstall the handlebar cover.

55

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.

CAUTION

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.

CAUTION

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

56

I (2.86 cm) from the outside edge of the track.

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 117.

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 trac-

tion accessories.

CAUTION

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.

57

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 107, 109

Steering System 62

Recoil Rope 63

Coolant Level 96

Parking Brake Lock/Brake Lever/Brake System 60, 61, 101

Auxiliary Shut-Off Switch (Engine Stop Switch) 64

Ignition Switch 64

Taillight/Brakelight/Headlight 64

Suspension Mounting Bolts 118

Skags (Wear Bars) 117

Ski Spindle Bolts 118

Hood Straps/Latches 63

Seat Latches (if equipped) N/A

Throttle Lever/Safety Switch 74, 75

Rear Wheel Idler Bolts 113

Tether Switch/Strap 64

Track Alignment/Condition 62, 114

Rail Slide Condition 118

Chaincase Oil Level 88

Injection Oil Level 71

58

PRE-RIDE INSPECTIONS

Before Starting the Engine

WARNING

Worn, damaged, or malfunctioning components may cause serious injury or
death. Before starting the engine, check all 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 74.

59

PRE-RIDE INSPECTIONS

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 103 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 102.

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.

1/2I (1.3 cm)

WARNING

60

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

3

2

4

2. Parking Brake Lever

Lock

3. Master Cylinder Reser-

voir/ Cover

1

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.

NOTE: 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 unlock 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.

61

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.

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.

NOTE: If your snowmobile is equipped with RIDER SELECT, perform

this check in both the full up and full down steering positions.

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.

NOTE: Track damage or failure caused by operation on ice or poor

62

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 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.

63

PRE-RIDE INSPECTIONS

Start the Engine and Check

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.

64

OPERATION

Starting the Engine

WARNING

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

Starting a Cold Engine

Do not depress the throttle until the
engine starts.

TOGGLE POSITIONS

1. Turn the fuel valve on. See page 29.

2. Turn the key to the ON position.

3. Pull the engine stop switch up to the

RUN position.

4. Flip the choke toggle to FULL ON.

HALF ON

5. If equipped with electric start, turn

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

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

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

CHOKE

OFF

FULL ON

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

WARNING

Don't pull the starter rope to the fully extended position and don't allow it to
snap back into the housing. Damage may result.

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

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

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

65

OPERATION

Starting the Engine

Starting a Warm Engine

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

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

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

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

NOTE: If the engine does not start after several attempts, slightly

depress the throttle (no more than 1/4
the engine. When the engine starts, immediately release the
throttle.

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.

CAUTION

I open), while cranking

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.

66

OPERATION

Engine Break-In

Oil Injection System

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

CAUTION

Serious engine damage can occur without the proper lubrication. Check the
oil tank level often during the first tank of fuel. If the oil level doesn't go down,
contact your dealer immediately.

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 122 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

CAUTION

Inadequate cooling and lubrication will lead to overheating of the slide rail
and track, resulting in premature wear and failure. Reduce speeds and fre­quently drive into fresh snow to allow adequate cooling and polishing of the
slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or
roads.

67

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.

NOTE: It will take longer to warm up the track

sufficiently during colder outdoor tem­peratures.

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

the machine to the ground.

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

to loosen snow and ice.

68

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.

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

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.

69

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).

CAUTION

Operating with obstructed fuel systems will result in serious engine damage.
Perform maintenance as recommended.

Prolonged exposure to petroleum based products may damage paint.
Always protect painted surfaces when handling fuel.

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 122 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.

70

OPERATION

Oil

n 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.

n 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.

CAUTION

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

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.

71

OPERATION

Carburetion

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

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

WARNING

Improper carburetor adjustments may result in operator safety hazards as
well as serious engine damage. Always have your Polaris dealer perform
any carburetor adjustments.

72

OPERATION

Carburetion

Jetting Guidelines

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

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

CAUTION

A main jet that's too small will cause a lean operating condition and may
cause serious engine damage. Jet the carburetors carefully for elevation and
temperature according to the jetting charts in your Owner's Manual Supple­ment.

NOTE: It's the owner's responsibility to ensure that the correct jets are

installed in the machine for a geographical area. Be very care­ful when jetting down in warm weather. As the weather turns
colder it will be necessary to re-jet upward to prevent engine
damage. When selecting the proper main jet always use the
lowest elevation and temperature that is likely to be encoun­tered.

73

OPERATION

n Engine Stop Switch

Push down on the engine
stop switch (9) to

9

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.

74

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 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.

75

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 74 for more information about the
engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES

Ignition Switch Interrupts ignition circuit All

Brake Slows jackshaft All

Choke Floods engine Half throttle or less

Engine Stop Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

Tether Switch (Option) Interrupts ignition circuit All

THROTTLE

CONDITION

76

OPERATION

Emergency Starting

If the recoil starter system fails, an emergency start strap is provided in
the tool kit.

1. Open the hood.

2. Remove the left side panel.

3. Using the belt removal tool,
follow the directions on the
air box to relieve belt tension.

4. Starting at one of the tower
struts, wind the strap counter­clockwise around the clutch
as shown.

WARNING

Serious injury can result from wrapping the start strap around your hand
while using the emergency starting procedure. DO NOT wrap the start strap
around your hand. Keep all bystanders and loose clothing away from the
snowmobile when using the emergency starting procedure.

5. Pull the strap abruptly so the strap comes free of the clutch while
starting the engine. Repeat until the engine starts.

6. Reinstall the side panel.

7. Close and secure the hood.

77

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.

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 machine is in reverse.

4. Apply the throttle slowly to make sure the machine is in reverse.

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

NOTE: 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.

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

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

78

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

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.

CAUTION

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.

79

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. The emission control system designation
per SAE J1930 is EM. 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.

80

MAINTENANCE

Emission Control Information

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty on
page 136, and read the maintenance section of your owner's manual.
You are responsible for ensuring that the specified maintenance is per­formed, including the emission-related maintenance outlined in these
sections of the manual.

You must inspect the air intake system on your snowmobile prior to
each use (including the airbox foam filter and hood foam filters) and
clean these components as necessary. Polaris considers the specified
maintenance for the spark plugs, oil changes, air intake system and
exhaust valves to be critical emission-related maintenance. The speci­fied maintenance for the fuel filter is recommended additional emission­related maintenance. Polaris recommends that you contact an autho­rized Polaris dealer to perform any service that may be necessary.

81

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 138.

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.

CAUTION

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.

82

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 107 II II

Clutches (disassemble) 106 CC C

Belt Tension -- II II

Clutch Sheaves 106 II II

Engine Mounts -- II II

Recoil Rope -- IIII

Engine Torque Stop 109 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 96 IIRI

Coolant Hose -- IIII

Heat Exchangers 98 II I I I

Coolant Circulation -- II I

Coolant Leaks -- IIII

Spark Plug Condition 91 II I RI

Exhaust Pipe 99 II

Exhaust Retaining
Springs

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

Page

150 mi.

(240 km)

106 II I

ENGINE/COOLING

99 II II

(800 km)

CLUTCH

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

83

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Hose Routing -- II II

Hose Condition -- IIII

Fluid Leaks -- IIII

Brake Pads 101 IIII

Brake Disc -- II II

Parking Brake 61 II II

Brake System 60,

Brake Fluid 102 R

Pilot Air Screws -- II I

Carburetor
(synchronize)

Idle RPM -- II I

Throttle Lever 75 II I II

Oil Pump Lever
(synchronize)

Throttle Cable 87 LL L

Choke Cable 87 LL L

Choke 87 II I

Vent Lines -- II II

Throttle Position
Sensor

Fuel Lines 93 II I I I

Fuel Filter 93 RR

Oil Filter 92 RR

Oil Lines 92 III

Air Box -- II I I I

Drain and Water Traps 95 II I

Auxiliary Shut-Off
Switch

Throttle Safety Switch 74 II I I I

Ignition Switch -- II I II

Taillight 64 II I II

Brakelight 64 II I I I

Headlight 64 II I I I

Page

150 mi.

(240 km)

101

FUEL MANAGEMENT

94 II I

-- II I

-- II I

ELECTRICAL

74 II I II

(800 km)

BRAKES

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

I

84

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 87 LL L I

Jackshaft Bearings 120 LL L I

Skags (Wear Bars) 117 II I I I

Ski Saddle/Spindle
Bolts

Drive Chain Tension 100 II I II

Hood Latches 63 II I I I

Rear Wheel Idler Bolts 113 II I II

Idler Bolt Jam Nut 113 II I II

Rear Suspension Pivot
Shafts

Steering Post U-Joint 86 LL L

Camber Alignment -- II I

Handlebar Centering -- I

Tether Switch and Strap 64 II I I I

Track Alignment 114 II I I I

Track Tension 112 II I I I

Front Limiter Strap -- II I I I

Rail Slide Condition 118 I

Chaincase Oil 88 II I RI

Page

150 mi.

(240 km)

-- II I II

-- II I II

-- II II

-- II I II

86 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

85

MAINTENANCE

Lubrication

Front Suspension

Lubricate the steering post U-joint (with engine fog­ging oil at the intervals outlined in the maintenance
charts beginning on page 82. Lubricate the U-joint
after seasonal storage as well as before seasonal
storage. See page 122 for the part numbers of
Polaris products.

The front suspension does not require lubrication.

Rear Suspension

Lubricate the suspension pivot shafts with Polaris Premium All Season
Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after
that, and before off-season storage each year. 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 Rear Suspension

9

9

9

SwitchBack Rear Suspension

86

9

9

9

9

9

9

9

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.

MAINTENANCE

9

9

Choke and Choke Cable

Lubricate the choke slide and cables
lightly with oil or grease. Before
turning the engine off, operate the
choke intermittently to draw mois­ture out of the choke plunger area
and reduce the possibility of the
choke becoming frozen.

9

87

MAINTENANCE

Lubrication

n Chaincase Oil

Check the chaincase oil level at the
intervals outlined in the maintenance
charts beginning on page 82. 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
122 for the part numbers of Polaris prod­ucts.

Oil Check

1. Position the vehicle on a level sur-

face.

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.

3

1

2

88

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.

NOTE: 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.

4

89

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).

CAUTION

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.

• 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.

90

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.

WARNING

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

NOTE: Incorrect fuel mixture can often cause a spark plug to appear

too dark or too light in color. Before changing spark plug heat
ranges, be sure the correct main jet is installed in the carbure­tor(s). Refer to the Owner's Manual Supplement or see your
dealer.

1. 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.

NOTE: 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.

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

91

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).

NOTE: The direction of the arrows

indicates the direction of
flow through the filter.

92

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.

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

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 in-tank fuel filter every
1000 miles (or annually).

9

CAUTION

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.

CAUTION

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

93

MAINTENANCE

Carburetor

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

CAUTION

Operating the snowmobile with incorrect jetting can result in serious engine
damage. Have your Polaris dealer perform all carburetor adjustments to
ensure all adjustments are done correctly.

Carburetor Adjustments

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

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

• Hard starting

• Poor idle

• Overheated pistons and cylinder walls

• Plug fouling

• Poor engine response to various throttle valve openings

94

MAINTENANCE

Carburetor Water/Sediment Trap

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

WARNING

When draining the traps, fuel spillage will occur. Always work in a well venti­lated area away from anything that may cause the fuel to ignite, such as open
flames, sparks, heaters, trouble lights, cigarettes, etc. Review the fuel warn­ings on page 69.

Cleaning Procedure

1. Turn the fuel valve off.

2. Place a container or shop
towels below the plug to
catch drained fuel.

3. Slide the clamp (1) away
from the drain plug (2) and
remove the drain plug from
the sediment tube.

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

5. Repeat the draining proce­dure for any remaining traps.

1

2

95

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 122 for Polaris products.

NOTE: Never add tap water to the cooling system. Minerals cause

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

deposits and may react adversely with the metals in the engine
and cooling system.

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.

CAUTION

Operating the snowmobile with insufficient coolant will result in overheating
and serious engine damage. Always maintain the coolant level as recom­mended.

96

MAINTENANCE

Cooling System

Coolant High Temperature Indicator Light

WARNING

Steam and hot liquids will cause serious 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.

NOTE: 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.

97