Polaris 600 IQ Touring 2010 Owner's Manual

Pantone 426C

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]
Part No. 9922288 Rev 01
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.

1

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world­wide family of Polaris owners. 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 recre-

ational 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!

2

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

RIDER SELECT is a trademark of Polaris Industries Inc.
Copyright 2009 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.
2010 600 IQ Touring Owner’s Manual
P/N 9922288

3

TABLE OF CONTENTS

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

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

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

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

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 50

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

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 64

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

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

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

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

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

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

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

4

5

INTRODUCTION

Important Notes for Owners and Drivers

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

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

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

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

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

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

6

INTRODUCTION

Preservation of the Environment

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

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

Noise Level

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

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

7

INTRODUCTION

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

Tunnel VIN (

+

): _________________________________________________________

(lower right side of the tunnel)

Engine Serial Number (on recoil housing): _____________________________________

Key Number: ___________________________________________________________

+

8

SAFETY

Operator Safety

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

The safety alert symbol, on your vehicle or in this manual, indicates the potential
for serious injury.

WARNING

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

CAUTION

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

NOTICE

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

9

SAFETY

Operator Safety

Follow the recommended maintenance program outlined beginning on
page 84 of this manual to ensure that all critical components on the
snowmobile are thoroughly inspected by your dealer at specific mileage
intervals.

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

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

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

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

WARNING

10

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.

11

SAFETY

Operator Safety

Riding Position

Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience; 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.

Survival Preparation

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

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

• Spare Drive Belt • Winter Survival Kit

• Extra Set of Spark Plugs • Trail Map

•Tow Rope •First Aid Kit

• Extra Oil • Tool Kit

• Fuel Deicer

12

SAFETY

Operator Safety

Riding Apparel

Helmet

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

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

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

Eye Protection

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

Clothing

Be prepared, be warm and be com­fortable when riding. Be aware of
the weather forecast, especially the
windchill, and dress accordingly.
See the chart on page 23.

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

E

4

051039

0006.31

13

SAFETY

Operator Safety

Rider Capacity

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

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

WARNING! Control becomes more difficult with two people on board. More
space is required to make turns, and longer distances are needed for stopping.
Make sure the passenger remains seated behind the driver, facing forward, with
both feet placed firmly on the running boards. Slow down and avoid “jumping”
your snowmobile.

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

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

14

SAFETY

Operator Safety

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and
physical skills.

WARNING! Operators with cognitive or physical disabilities have an increased
risk of loss of control, which could result in serious injury or death. Do not allow
disabled persons to operate this vehicle.

Cargo Overload

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

15

SAFETY

Operator Safety

Excessive Speed

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

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

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

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

16

SAFETY

Operator Safety

Driver Awareness

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

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

Variances in snow depth and/or water currents may result in uneven ice
thickness. You may drown if you break through the ice. Avoid travelling
on frozen bodies of water.

RR

17

SAFETY

Operator Safety

Avalanches

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

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

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

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

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

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

18

SAFETY

Operator Safety

Ice and Snow Build-up

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

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

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

If your snowmobile is equipped with RIDER SELECT, perform this
check in both the full up and full down steering positions.

Driving Downhill

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

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

19

SAFETY

Operator Safety

Driving on Slippery Surfaces

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

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

Driving in Hilly Terrain

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

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

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

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

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

20

SAFETY

Operator Safety

Drive Belt

Do not operate the engine with the drive belt removed.

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

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

to the engine.

Intake Silencer

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

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

removed.

Clutches

Do not attempt to service the clutches.

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

Cold Weather Drive-Away

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

Maneuverability

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

21

SAFETY

Operator Safety

Inadequate Snow Conditions

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

NOTICE: Driving in too little snow will result in excessive wear and damage to

the slide rail, track and/or engine.

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

Operating in Deep Snow

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

22

SAFETY

Operator Safety

Driving Responsibly

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

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

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

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

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

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

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

23

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WIND CHILL CHART (°F)

WIND CHILL CHART (°C)

Wind

Speed

in

MPH

Actual Thermometer Reading (_F)

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

Equivalent Temperature (_F)

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

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

5 3631251913 7 1 -5-11-16

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

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

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

15 32 25 19 13 6 0 -7 -13

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

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

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

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

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

30 28 22 15 8 1 -5 -12

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

35 28 21 14 7 0 -7 -14

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

40 27 20 13 6 -1 -8 -15

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

45 26 19 12 5 -2 -9 -16

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

50 26 19 12 4 -3 -10 -17

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

55 25 18 11 4 -3 -11

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

60 25 17 10 3 -4 -11

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

Frostbite in >>

30 min. 10 min. 5 min.

Wind

Speed

in

KPH

Actual Thermometer Reading (_C)

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

Equivalent Temperature (_C)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Frostbite in >>

30 min. 10 min. 5 min.

24

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 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:

WARNING

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

25

SAFETY

Safety Decals and Locations

Passenger Warning

Snowmobiles designed for an
operator and one passenger have a
warning decal on the left console.
For more information on operating
with a passenger, see page 13.

WARNING

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

Track Warning

WARNING

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

“One Passenger”

Warning

Track Warning

26

SAFETY

Safety Decals and Locations

Reverse Warning

Polaris snowmobiles equipped with electric reverse and will have this
decal on the console:

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.

Reverse Warning

Operation

Warning

27

SAFETY

Safety Decals and Locations

Operation Warning

An operation warning decal is present on the console of all Polaris
snowmobiles:

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

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

WARNING

28

FEATURES

1. Nosepan

2. Skis

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

4. Hood

5. Headlight

6. Windshield

7. Operator Seat

8. Passenger Seat

9. Backrest

10. Passenger Grab Handle

11. Cargo Bag

12. Grab Handle Heater Switch

13. Taillights

14. Rear Bumper

15. Snow Flap

16. Track

17. Suspension

3

4

5

6

2

1

7

8

9

12

13

14

15

16

17

10

11

29

FEATURES

1. MFD Display

2. Mirrors

3. Rider Selectt

4. Fuel Filler Cap

5. Handlebar

6. Hood Hold Down

Straps

7. Handlebar Grip Warmer

Switch

8. Thumbwarmer Switch

9. Electronic Reverse

Button

10. MFD Control

11. Headlight Dimmer

Switch

12. Parking Brake Lock

13. Brake Lever

14. Engine Stop Switch

15. Throttle Control

16. Ignition Switch

16

1

13

14

15

12

7

8

9

10

11

3

1

6

4

5

30

FEATURES

Backrest

The backrest is adjustable for either
operator or passenger use.

1. Loosen the upper adjustment
knobs to raise or lower the
backrest.

2. Loosen the lower adjustment
knobs to move the backrest for­ward for operator use or rear­ward for passenger use.

3. Always tighten the knobs
securely after adjusting.

Adjustable Headlights

Move the adjuster to the left to lower the
headlight beam.

Move the adjuster to the right to raise the
headlight beam.

Radiator Compartment
Access Panel

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

Operator/Passenger

Raise/Lower

+

31

FEATURES

Cargo Bag

The cargo bag is secured to the rear of
the tunnel with straps. The cargo bag
and the passenger seat are removable to
provide open storage for transporting
larger items. The maximum weight
capacity for the cargo area is 30 lbs.
(14 kg). Always secure cargo before
operating. Do not exceed the weight
limit. Do not allow a passenger to sit on
the seat back or the cargo area.

1. Remove the cargo bag.

2. Push down on the seat latch lever,
which is located at the lower rear
of the passenger seat.

3. Lift up the seat and remove it from
the chassis.

4. Reverse the procedure to reinstall
the seat. Press down firmly on both
sides of the seat to engage the
latch. Verify that the latch is
engaged by firmly pulling the seat
upward.

Cargo Bag

Seat Latch

32

FEATURES

Passenger Grab Handle

On some models the position of the
passenger grab handles can be
adjusted for rider preference.

1. Unscrew and remove the knob
assemblies that secure the grab
handles.

2. Reposition the grab handles to
one of the three available posi­tions on the grab handle tube
between the operator seat and the
passenger seat.

3. Reinstall the knob assemblies and
tighten securely.

Knob
Assembly

33

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. Some
models have five (5) adjustment positions. Other models have seven (7)
positions.

WARNING! If your snowmobile has five adjustment positions, do not remove
the RIDER SELECT lockout. Your Polaris snowmobile has been engineered for
this range of adjustability. Removing this lockout and using RIDER SELECT
position 6 or 7 will result in the handlebars and brake lever contacting other
components and interfering with steering and braking. This could lead to loss of
control resulting in serious injury or death. Always be sure that the handlebars
and brake lever do not contact any other snowmobile components at any
steering position AND at any RIDER SELECT position.

Do not use RIDER SELECT positions 6 or 7 unless riding conditions require it.
Operation in position 6 or 7 can reduce vehicle handling for other types of riding
and result in serious injury or death.

Choosing the Best RIDER SELECT Position

Position Riding Style

1
2
3

Relaxed Trail Riding

Rider weight is slightly behind the center
of the snowmobile for comfortable and
relaxed riding.

45General Trail Riding, Boondocking,

Deep Snow Riding

Rider weight is centered on the snowmo­bile, providing balance, comfort and con­trol for both novice and experienced
riders. This is the recommended position

for most riding situations.

67Snowcross/Steep Hill Climbing Only

Rider weight is ahead of the center of the
snowmobile, adding weight to the skis and
making the snowmobile heavier in the
front. These positions are ONLY for
snowcross and severe hill climbing.

34

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.

WARNING! 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.

35

FEATURES

Detonation Elimination Technology (DET)

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

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

Sensor Fail-Safe

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

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

connected.

Cause of DET Activation Solution

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

36

FEATURES

Instrumentation

MFD Component Identification

Digital Display Identification

Item

1 Analog (if equipped)

2 Digital Gauge

3 CHECK ENGINE

Indicator (carb models)

4 Low Oil Indicator

5 High Temp Indicator

6 Brake Indicator

7 Reverse Indicator

8 High Beam Indicator

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

4 Air Temp (if equipped)

Engine Temp
Degrees Celsius
Degrees Fahrenheit

5Miles

Kilometers

6Hours

Trip 1/Trip 2/Trip F
Service Label
Altitude Label

7 Fuel Level (if equipped)

1

2

3

5

6

7

8

4

1

2

3

4

5

6

7

37

FEATURES

Instrumentation

MFD Settings

The MFD control switch allows you
to set the MFD display to your pref­erences. The rocker switch has a
MODE button (top) and a SET but­ton (bottom). Specific instructions
are outlined on the following pages.

Standard vs. Metric

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

MFD Control Switch

SET

MODE

38

FEATURES

Instrumentation

MFD Settings

Speedometer/Tachometer

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

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

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

Option

Analog

Display

Digital

Display

Analog
Screen

Digital

Screen

1 Speed RPM Blue “MPH” Blue

Backlight

2 RPM Speed Red

“X100RPM”

Red

Backlight

39

FEATURES

Instrumentation

MFD Digital Display Programs

Press and release the MODE button to cycle through the three MFD pro­grams: Performance, Engine and History. Each program remains active
until you cycle to the next program. While any program is active, press
and release the SET button to cycle through the program’s screens.

Performance Program

The Performance Program automatically displays either speed or
tachometer, whichever is opposite the analog display. See page 38. It
also displays electrical system voltage and fuel level (if equipped).

While in the Performance mode, press the SET button to cycle through
the odometer, Trip 1, Trip 2, Trip F (if equipped with electronic fuel
gauge) and Clock (if equipped). Use the following procedures to make
changes to these screens.

Odometer Setting

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

40

FEATURES

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. Both
odometers can be reset to zero.

1. Enter the Performance Program.

2. Press and release the SET button
until the desired trip screen is
active.

3. Press and hold the SET button for two seconds to reset the trip
odometer to zero.

4. Press and release the SET button to cycle through additional
screens.

41

FEATURES

Instrumentation

MFD Digital Display Programs

Performance Program

Trip Settings

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.

42

FEATURES

Instrumentation

MFD Digital Display Programs

Performance Program

Clock Setting (if equipped)

1. Enter the Performance Program.

2. Press and release the SET button
until the clock screen is active.

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

4. When the hour starts flashing,
press the SET switch once to advance one hour. (Press and hold the
SET button to advance the hours quickly.)

5. Press and release the MODE button to save the hour. The minutes
will begin flashing.

6. Set the minutes in the same manner.

7. When finished, press and release the MODE button to save the new
setting. If the MODE button is not pressed within ten seconds, the
gauge will automatically save the new entry.

43

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. Use the following
procedures to make changes to these screens.

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.

Air Temperature (if equipped)

The MFD displays actual air temperature in
either standard or metric units.

1. Enter the Engine Program.

2. Press and hold the MODE switch for ten
seconds to switch between standard and
metric units of measurement.

44

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.

1. Enter the Engine Program.

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

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

2. Press and release the SET button until the altimeter screen is active.

3. Press and hold the SET button for five seconds. When the digits
begin to flash, release the button.

4. Press and release the SET button once to advance 50 feet (15 m).

Tip: Press and hold the SET button to advance quickly by 100-foot (30 m) incre-

ments.

5. Adjust the altitude display to within 50 ft. (15 m) of current altitude.

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

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

6. Press and release the MODE button to set the reading at the adjusted
value. If the MODE button is not pressed within ten seconds, the
gauge will automatically save the new entry.

45

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

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

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

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

Maximum Speed/Maximum RPM

1. Enter the History Program.

2. Press and release the SET button until
one of the two screens is active.

Tip: The MPH and RPM values are both reset at

the same time. Reset the values before each
run to obtain accurate readings.

3. Press and hold the SET button for three
seconds to reset the recorded maximum
values for both MPH and RPM.

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

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

46

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

Service Interval Reminder

The gauge logs the number of engine
hours accumulated 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 engine is started
(until the service reminder is reset.) Use
the following procedures to reset the
reminder.

To reset the reminder at the existing interval:

1. Enter the History Program.

2. Press and release the SET button until the service interval screen is
active.

3. Press and hold the SET button for ten seconds, continuing to hold
even after the display begins to flash.

4. When the display stops flashing, release the button. The service
interval has been reset.

47

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

Service Interval Reminder

To reset the reminder at a new interval:

1. Enter the History Program.

2. Press and release the SET button until the service interval screen is
active.

3. Press and hold the SET button for five seconds, until the hours begin
to flash. Immediately release the button.

4. Press the button again, up to five times, to advance the reminder in
50-hour increments.

Tip: The maximum interval is 250 hours.

5. Press and release the MODE button to save the new settings.

To disable the service interval reminder:

1. Press the SET button once after reaching 250 hours on the display.
The gauge will display "OFF".

48

FEATURES

Instrumentation

MFD Battery Replacement

Models equipped with the clock feature
have a battery to power the clock. If the
clock function of the MFD isn't working
properly, replace the battery. Replace­ment batteries are available from your
dealer.

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

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

3. Cut the plastic cable tie from the
outside of the compartment.

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

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

installed battery will not maintain the clock.

49

FEATURES

Instrumentation

MFD Battery Replacement

5. Using needle-nose pliers, grasp the battery and rotate it so the lead­ing edge of the battery is raised away from the battery holder. Pull
the battery out gently.

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

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

6. Install a new battery with fingers only.

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

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

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

Gauge Cleaning

1. Wipe the gauge face as needed using a clean cloth and a mild soap
and water solution. Wipe dry with clean, soft cloth.

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

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

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

50

THE PERFECT FIT

IQ Front Suspension Adjustments

Independent Front Suspension (IFS)

Break in the suspension for approximately 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 snowmobile should be methodically tested,
one change at a time, under the same conditions (trail and snow condi­tions, vehicle speed, riding position, etc.) after each adjustment until the
best ride is achieved.

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

1

2

3

4

51

THE PERFECT FIT

IQ Front Suspension Adjustments

Front Shock Spring Preload

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

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

Increasing the spring preload too much
may adversely affect the handling of the
snowmobile and the performance of the
suspension. Never exceed one inch of pre­load beyond the factory settings, and
ensure that both sides are adjusted the
same. When decreasing preload, make
sure at least two turns of preload are hold­ing the spring between the retainer on the
top of the shock and the threaded spring
preload adjuster nut on the shock body.
Failure to do so could cause the retainer to fall off when the suspension
is fully extended.

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

dealer for more information.

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

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

Low

Preload

High

Preload

52

THE PERFECT FIT

IQ Front Suspension Adjustments

Shock Valving

The 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.

53

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 snow-cross racing would provide a
very stiff ride on the trail. A suspension set up for trail riding would bot­tom out harshly on a snow-cross 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.

Suspension Performance Tips

• Rider weight usually determines the position at which the spring pre-

load should be set. However, this may vary with riding style. With a
little experimentation, each rider can find a preferred set-up. These
adjustments are easy to make, involve very little time or effort, and
greatly affect the ride.

• In deep snow, a new rail slide will offer improved performance over a

worn slide. It can also improve top speed.

• When riding on ice or hard-packed snow, adding a set of bogie wheels

to the rail may enhance the machine's performance. Bogie wheel kits
are available from your dealer.

• Polaris offers track kits for improved flotation in deep snow. See your

dealer for assistance.

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

rust build-up and ensure proper function of the suspension components.
Grease rear suspension pivots before adjusting the rear suspension. Refer
to the suspension lubrication information beginning on page 89.

54

THE PERFECT FIT

IQ 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.

Tip: 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.

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

preference and riding conditions. Accessory springs with a higher load rat­ing are available for some models. Please see your dealer for availability.

Suspension Recommended Sag Adjustment

See

Page

IQ Comfort

(136)

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

Preload

55

X

Y

55

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

56

THE PERFECT FIT

IQ Rear Suspension Adjustments

Limiter Strap Position (Ski Pressure)

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

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

2. Relocate the straps to the desired position.

3. Reinstall the nuts and washers. Tighten securely.

Upper

Nuts

57

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.

58

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.

• Increased load carrying capacity (2-up)

59

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.

Tip: Your dealer can help you with initial

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

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.

HIGH

LOWLOW

MEDIUM

60

THE PERFECT FIT

Handlebar Adjustments

Use the RIDER SELECT feature to adjust handlebar position. See page

33. Use the following steps to adjust handlebar angle at the handlebar

block.

1. Remove the handlebar cover
to expose the handlebar and
the four adjuster block bolts.

2. Using a 7/16" wrench, loosen
the four nuts on the bottom of
the adjuster block (turn han­dlebar to left or right for
access to back nuts).

Tip: If necessary, pry the blocks apart

with a screwdriver.

3. Adjust the handlebar to the
desired height. Be sure han­dlebars, brake lever and
throttle lever operate
smoothly and do not hit the
gas tank, windshield or any
other part of the machine
when turned fully to the left
or right.

4. Torque the front bolts first, then torque the rear bolts. Torque the
bolts to 15-17 ft. lbs. (20-23 Nm).

5. Reinstall the handlebar cover.

Handlebar
Cover

Adjuster
Block
Bolts

Nuts

61

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.

62

THE PERFECT FIT

Traction Products

Studs

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

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

See your dealer about installing studs and/or carbides.

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

strips may result in cooler or tunnel damage. See page 63.
Never add shims to the wear strip. Track damage will result because

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

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

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

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

NOTICE: Aggressive studding patterns may require grinding protruding stud

bolts flush to prevent idler wheel damage. Maintain track tension on
studded tracks on the tight side of the spec to prevent heat exchanger
damage. Center of stud must be at least 1 1/8" (2.86 cm) from the
outside edge of the track.

63

THE PERFECT FIT

Traction Products

n Carbide Skags

A skag is a replaceable bar attached to the underside of the ski to assist
in turning the snowmobile and to prevent ski wear caused by contact
with roads and other bare terrain. Use carbide skags with studded tracks
to help maintain proper vehicle steering and control. See page 115.

If your snowmobile has carbide skags, it may be necessary to add track
studs to maintain proper vehicle control. Maintain a proper balance
between the number of studs and the length of carbide on the skags (the
more studs you use, the longer the carbide on the skags should be). See
your dealer's track studding chart.

Wear Strips

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

Install the appropriate wear strip kit. See your dealer.

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

NOTICE: Whenever wear strips are relocated, be sure there's adequate stud

clearance to the heat exchangers. Lack of clearance may result in
damage to heat exchangers.

64

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 105

Steering System 66

Recoil Rope 65

Parking Brake Lock/Brake Lever/Brake System 67, 68, 100

Throttle Lever 65

Throttle Safety Switch 65

Auxiliary Shut-Off Switch (Engine Stop Switch) 71, 81

Ignition Switch 71, 81

Taillight/Brakelight/Headlight 71

Coolant Level 96

Chaincase Oil Level 90

Injection Oil Level 77

Suspension Mounting Bolts 70

Skags (Wear Bars) 63, 115

Ski Saddle and Spindle Bolts 70

Hood Straps/Latches 66

Seat Latches 65

Rear Wheel Idler Bolts 70, 111

Track Alignment/Condition 69, 112

Rail Slide Condition 112

65

PRE-RIDE INSPECTIONS

Before Starting the Engine

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

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

Read and Understand Your Owner's Manual

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

n Throttle Lever

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

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

n Throttle Safety Switch

Test the throttle safety switch system before the snowmobile is operated.
See page 78 for procedure.

n Seat Latches

Ensure that the seat latches are securely in place before every use of the
snowmobile.

n Recoil Rope

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

66

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 Steering System

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

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

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.

If your snowmobile is equipped with RIDER SELECT, perform this
check in both the full up and full down steering positions.

67

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 1/2" (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 102.

Brake Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 101.

Check for the presence of air in the fluid system. See page 102 for more
information, or see your dealer for service.

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

1/2" (1.3 cm)

68

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Parking Brake Lever Lock

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

1. Brake Lever

2. Parking Brake Lever Lock

3. Master Cylinder Reservoir/Cover

4. Fluid Level Indicator

Lock Engagement

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

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

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

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

Lock Release

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

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

12

34

69

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Track Inspection

WARNING! Operating the snowmobile with a damaged track increases the

possibility of track failure, which could cause loss of control resulting in serious
injury or death. Always inspect the track for damage before using the vehicle.

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

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

70

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Suspension Inspection

Loose nuts and bolts can reduce your snowmobile's reliability and cause
needless repairs and down time. Before beginning any snowmobile trip,
a visual inspection will uncover potential problems. Check the follow­ing items on a weekly basis or before any long trip.

Item Check Page

Suspension mounting bolts Tightness --

Rear idler wheel bolts Tightness 111

Rear idler adjusting bolt locknuts Tightness --

Torque arm bolts Tightness --

Carrier and bogie wheel bolts Tightness --

Front torque arm limiter strap Condition --

Rail slide Condition 112

Track Tension 110

All rear suspension components Lubrication 88

Ski runner/skag Condition --

Ski spindle bolts Tightness --

Tie rod end nuts Tightness --

71

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 Lighting

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

n Mirror Adjustment

If equipped, adjust your mirrors so they can be used to their full advan­tage.

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 Operating Area

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

72

OPERATION

Engine Break-In

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

NOTICE: Excessive heat build-up during the first three hours of operation will

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

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

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

73

OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil tank when refueling. See page 77.

NOTICE: 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 118 for the part numbers of Polaris products.

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

Slide Rail and Track Cooling

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

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.

74

OPERATION

Track Warm-Up

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. Be sure the rear support is stable.

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

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

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

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

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

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

temperatures.

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

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

WARNING

WARNING

75

OPERATION

Fuel Safety

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

• Always turn off the engine before refueling.

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

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

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

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

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

WARNING

WARNING

76

OPERATION

Fuel

For peak performance, Polaris recommends the use of 91 octane or
higher fuel. Although 87 octane fuel is usable, some engine perfor­mance will be lost and fuel economy will decrease. Do not use lower
than 87 octane fuel. Do not use fuel containing more than 10% ethanol
(including E85).

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

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 118 for the part numbers of Polaris products.

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

77

OPERATION

n Oil

Low Oil Indicator Light

The low oil indicator light will alert the operator if the oil level is low.
Visually check for oil in the bottle. Add oil before further operation of
the snowmobile. See page 73 for oil recommendations.

Low Oil Level

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

NOTICE: Operating the snowmobile without adequate engine lubrication can

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 73 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.

78

OPERATION

n Engine Stop Switch

Push down on the engine stop
switch to ground out the ignition
and stop the engine quickly. Pull the
switch up to the RUN 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.

Stop Switch

79

OPERATION

n 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 throttle body to determine

what caused the safety switch to activate.

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

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

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

go through normal starting procedures.

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

Polaris dealer for service.

Tip: Excessive freeplay in the throttle cable may cause the safety switch to acti-

vate, preventing the engine from starting. If this occurs, return the snowmo­bile to an authorized Polaris dealer for service.

Tip: 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.

80

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 gearcase 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 snowmobile before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

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

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

Engaging Reverse

1. Stop the snowmobile and

leave the engine idling.

2. Make sure the area behind

your snowmobile is clear.

3. Push the yellow reverse but-

ton on the left-hand control
for one second, then release.

Tip: A reverse light on the instrument panel will indicate that the transmission is

in reverse.

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

reverse.

Tip: If the engine stops running, the transmission will be in forward gear when

it's restarted.

Reverse Button

81

OPERATION

Electronic Reverse (PERCt)

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

on the instrument panel will shut off.

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

ward.

n Emergency Stopping

The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 78 for more information about the
engine stop switch.

SYSTEM WHAT IT DOES

Ignition Switch Interrupts ignition circuit

Brake Slows jackshaft

Engine Stop Switch Interrupts ignition circuit

Throttle Safety Switch Interrupts ignition circuit

Tether Switch (Option) Interrupts ignition circuit

82

OPERATION

Daily Storage

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

Remove the key and cover the snowmobile.

Towing

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

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

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

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

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

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

83

MAINTENANCE

Emission Control Information

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

Emission Control Label

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

Emission Control Maintenance Requirements

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

Owner's Responsibilities

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

84

MAINTENANCE

Polaris Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow
recommended regular maintenance and perform service checks as out­lined in this manual. Record maintenance and service in the Mainte­nance Log beginning on page 133.

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

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

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

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

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

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

85

MAINTENANCE

Periodic Maintenance Interval Table

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

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

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CLUTCH

Clutch Alignment Offset
(without belt)

104 II I

Drive Belt Condition 105 II II

Clutches 104 CC C

Belt Tension -- II II

Clutch Sheaves 104 II II

ENGINE/COOLING

Engine Mounts -- II II

Recoil Rope -- IIII

Engine Torque Stop 107 II II

Cylinder Head Bolts -- II I

Cylinder Base Nuts -- II I I

Ignition Timing BTDC -- II I

VES System -- CC C I

Coolant 96 IIRI

Coolant Hose -- II II

Heat Exchangers 98 II I I I

Coolant Circulation -- II I

Coolant Leaks -- II II

Spark Plug Condition 92 II IRI

Exhaust Pipe 95 II

Exhaust Retaining
Springs

95 II II

86

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

BRAKES

Hose Routing -- II II

Hose Condition -- IIII

Fluid Leaks -- IIII

Brake Pads 100 IIII

Brake Disc -- IIII

Parking Brakes 68 II II

Brake System 67,

100

I

Brake Fluid 101 R

FUEL MANAGEMENT

Idle RPM -- III

Throttle Lever 65, 79 II I I I

Oil Pump Lever
(synchronize)

-- III

Throttle Cable 89 LL L

Throttle Position
Sensor

-- III

Fuel Lines 94 II I I I

Fuel Filter 94 RR

Oil Filter 95 RR

Oil Lines 95 III

Air Box -- II I I I

ELECTRICAL

Auxiliary Shut-Off
Switch

71, 78 II I I I

Throttle Safety Switch 78 II I I I

Ignition Switch -- II I I I

Taillight 71 II I I I

Brakelight 71 III I I

Headlight 71 II I I I

87

MAINTENANCE

Periodic Maintenance Interval Table

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

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CHASSIS

Ski Toe Alignment -- II I

Suspension Mounting
Bolts

-- II I I I

Steering Fasteners -- II I IC

Rear Suspension Fas­teners

-- II I I I

Suspension Shock Oil -- II II

Cooling Fins and
Shroud

-- II II

Drive Shaft Bearing 89 LL L I

Jackshaft Bearings 116 LL L I

Skags (Wear Bars) 115 II I I I

Ski Saddle/Spindle
Bolts

-- II I I I

Drive Chain Tension 99 II I I I

Hood Latches 66 II I I I

Rear Wheel Idler Bolts 111 II I I I

Idler Bolt Jam Nut 111 II I I I

Rear Suspension Pivot
Shafts

88 LL L

Steering Post U-Joint -- LL L

Camber Alignment -- II I

Handlebar Centering -- I

Tether Switch and Strap 71 II I I I

Track Alignment 112 III I I

Track Tension 110 II I I I

Front Limiter Strap -- II I I I

Rail Slide Condition 112 I

Chaincase Oil 90 II I RI

88

MAINTENANCE

Lubrication

Rear Suspension

Lubricate the suspension pivot shafts with Polaris Premium All Season
Grease at the intervals outlined in the Periodic Maintenance Table
beginning on page 85 and before seasonal storage. When operating in
heavy, wet snow conditions, lubricate every 500 miles (800 km).

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

IQ Comfort Rear Suspension

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89

MAINTENANCE

Lubrication

Driveshaft Bearing

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

Throttle Cable

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

Front Suspension

The front suspension and steering components do not require lubrica­tion.

Fitting

90

MAINTENANCE

n Chaincase Oil

Check the chaincase oil level at the
intervals outlined in the Periodic Main­tenance Table beginning on page 85.

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

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

Oil Check

1. Position the vehicle on a level 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.

1

3

2

91

MAINTENANCE

Chaincase Oil

Oil Change

1. Position the vehicle on a level surface.

2. Remove the drain plug (4) and drain

the oil into a drain pan. Allow the oil
to drain completely.

3. Clean off all metal shavings from the

plug.

4. Install a new sealing washer on the

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

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

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

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

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

4

92

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.

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

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

• Use recommended spark plugs with the proper gap. Refer to your
Owner's Manual Supplement for the specific spark plug to be used in
your machine.

• Use only resistor-type spark plugs.

• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).

Check the spark plug firing end condition after the engine has been
warmed up and the vehicle has been driven at higher speeds. If a plug is
fouled, replace the plug with a new plug.

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

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MAINTENANCE

Spark Plugs

Normal Spark Plug

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

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

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

Wet Fouled Spark Plug

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

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.

94

MAINTENANCE

Intake Filters

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

Fuel Injectors

All fuel injector service must be performed by an authorized Polaris
dealer. Do not attempt to clean or service the fuel injectors.

Fuel Pump

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

Fuel Filter

See your Polaris dealer for replacement of the fuel filter at the intervals
outlined in the Periodic Maintenance Table beginning on page 85.

Fuel Lines

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

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

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

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MAINTENANCE

Oil Lines

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

Oil Filter

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

Tip: The direction of the arrows indicates

the direction of flow through the fil­ter.

Exhaust System

Check the exhaust system for wear or damage at the intervals outlined in
the Periodic Maintenance Table beginning on page 85.

CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for
the exhaust system to cool. Never perform this procedure with the engine
running.

1. Allow the engine and exhaust system to cool completely.

2. Open the hood.

3. Inspect the muffler and pipes for cracks or damage. Check for weak

or missing retaining springs or damper/support grommets.

4. Replace any damaged or missing components.

5. Close the hood.

96

MAINTENANCE

Cooling System

Coolant

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

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

Tip: Never add tap water to the cooling system. Minerals cause deposits and

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

n Coolant Level

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

• Coolant reservoir bottle

• Filler neck

• Pressure cap

• Connecting hoses

Always maintain the coolant level at the “COLD FILL” mark on the
coolant overflow tank (when the engine is cold).

NOTICE: Operating the snowmobile with insufficient coolant will result in

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

97

MAINTENANCE

Cooling System

Coolant High Temperature Indicator Light

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

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

Flushing the Cooling System

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