Polaris 600 IQ Widetrak 2014 Owner's Manual

PMS 419

Snowmobile Owner's Manual

for Maintenance and Safety

600 IQ

Widetrak

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

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• VICTORY® motorcycles

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

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

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

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

2

POLARIS and IQ are registered trademarks of POLARIS Industries Inc.
Copyright 2013 POLARIS Sales Inc. All information contained within this publication

is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies may result between the actual vehicle and the information presented in this publi­cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.

Printed in U.S.A.
2014 600 IQ Widetrak Own er’s Manual
P/N 9924294

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 . . . . . . . . . . . . . . . . . . . . . . . . . 46

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

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 54

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 114

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 116

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 117

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 131

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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. Te ach 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.

Air Pollution

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

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

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 (X): __________________________________________________________
(right side of the tunnel)

Engine Serial Number (on valve cover): _______________________________ ________

Key Number: ____________________________________________________________

X

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 indicates a potential personal injury ha zard.

DANGER

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

WARNING

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

CAUTION

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

NOTICE

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

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

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

9

SAFETY

Operator Safety

Follow the recommended maintenance program outlined beginning on
page 75 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 opera ting
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
Transportati on (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

Your snowmobile is designed for up to two riders. A decal on the
console indicates that the vehicle is designed for one operator and one
passenger only.

WARNING! Operating improperly with a passenger could cause loss of control
and result in serious injury or death. 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” the snowmobile.

Snowmobiles designed for two riders should never be operated with
more than two people on board. 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

Cargo Capacity

See page 32 for cargo loading information.

WARNING! Overloading the cargo carrier can cause loss of control resulting in
severe injury or death. The maximum cargo carrier capacity is 75 lbs. (34 kg).
Never exceed the cargo carrier capacity.

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.

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 be alert and pay attention to the trail ahead. If your speed is 40
MPH (16 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. Never travel on
frozen bodies of water unless you have first verified that the ice is suffi­ciently thick to support the weight and moving force of the snowmobile,
you and your cargo, together with any other vehicles in your party.
Always check with local authorities and residents to confirm ice condi­tions and thickness over your entire route. Snowmobile operators
assume all risk associated with ice conditions on frozen bodies of water.

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

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 abov e 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 dif ficulty
is encountered, remove ice and snow build-up that may be obstructing
the steering linkage.

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.

CAUTION! Operation of the engine with the belt removed may result in
personal injury or damage to the engine.

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

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. Warm the drive belt by allow­ing the engine to idle in neutral for several minutes. 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.

If the snowmobile is carrying a load and is equipped with a high/low
transmission, drive in low gear the first several feet, then stop and shift
to high gear.

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 th e
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

Km/h

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 pro-
vided by POLARIS at no charge. The part number is printed on the
decal.

Clutch Warning

This warning decal is found under the hood on the air plenum:

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 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.

Track

Warning

26

SAFETY

Safety Decals and Locations

Reverse Warning

POLARIS snowmobiles equipped with standard 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 turn s.

• Shift to or from reverse only when stopped.

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

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:

WARNING

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

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

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

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

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

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

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

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

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

• To maintain vehicle control on ice or hard-packed surfaces, you
should have a proper balance of ski carbides to track st uds. 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 se ated and in posi­tion to control the vehicle.

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

28

FEATURES

3

4

5

6

12

2

1

9

10

11

13

14

15

16

17

18

7

8

1. Nosepan

2. Skis

3. Front Bumper

4. Hood

5. Headlight

6. Windshield

7. Mountain Bar

8. Handlebar

9. Seat

10. Backrest

11. Taillights

12. Cargo Carrier

13. Rear Bumper

14. Snow Flap

15. Track

16. Suspension

17. Passenger Grab Handle

18. Seat Latch

19. Fuel Filler Cap

19

29

FEATURES

2

5

6

14

7

8

12

13

3

10 9

1

4

1. Glove Box

2. MFD Display

3. Ignition Switch

4. Shifter

5. Recoil Starter Handle

6. Brake Lever

7. Handlebar Grip Warmer
Switch

8. Thumbwarmer Switch

9. Throttle Control

10. Engine Stop Switch

11. Electronic Reverse Button

12. MFD Control Switch

13. Headlight Dimmer Switch

14. Parking Brake Lock

11

30

FEATURES

Backrest

The backrest can be adjusted for rider comfort. Whenever making
adjustments, always make sure all lock levers are securely locked before
operating.

Tip: If an adjustment is difficult, rotate the lock levers counter-clockwise to

relieve tension, then make the adjustment. Always tighten the levers after
adjusting.

Height Adjustment

1. Lift the upper lock levers (A)
on both backrest supports to
release the locks.

2. Raise or lower the backrest to

the desired position.

3. Push the lock levers inward to

secure the locks. Rotate
levers clockwise to tighten.

Angle Adjustment

1. Lift the lock lever at the center of the backrest (B).

2. Tilt the backrest forward or rearward to the desired position.

3. Push the lock lever inward to secure the lock.

Operator/Passenger Conversion

1. Lift the lower lock levers (C) on both backrest supports to release

the locks.

2. Move the backrest forward for operator use or rearward for

passenger use.

3. Push the lock levers inward to secure the locks. Rotate levers clock­wise to tighten.

Adjustable Headlights

Move the headlight adjuster to raise or
lower the headlight beam.

• Move the adjuster to the left to lower

the beam.

• Move the adjuster to the right to raise

the beam.

A

C

B

31

FEATURES

Shifter

For normal operation, place the
transmission in high gear. When­ever towing or operating with a
heavy load, place the transmission
in low gear. See page 73. When
operating in low gear, vehicle speed
will be limited to protect the drive
train.

Glove Box

The glove box is a heated dry stor­age area intended for drying wet
gloves. Do not use the glove box for

items that could be damaged by
heat.

Turn the knob to release the glove box cover latch and open the cover.

Seat Latch

Release the seat latch and raise the seat to
access the battery and under-seat storage
area.

Check the seat latch before each use of
the snowmobile. Push downward on the
seat near the seat latch, then attempt to
raise the seat by pulling upward on the
right-hand passenger grab handle. Make
sure the latch is secure before riding.

Under-Seat Storage

When using the under-seat storage area
to transport supplies and other items,
pack the items securely to prevent them
from moving around in the storage area.
Smaller items should be placed in bags or
containers to keep them secure.

Glove Box Latch

Shifter

Seat Latch

Storage Area

32

FEATURES

12-Volt DC Outlet

Use the 12-volt DC outlet to power a global positioning sensor (GPS),
heated helmet shield, utility light, cell phone or other accessories. The
outlet is located on the console near the ignition switch.

Cargo Carrier

Whenever towing or operating with a heavy load, place the transmission
in low gear. See page 73.

WARNING! Overloading or towing
improperly can alter vehicle
handling and can cause loss of
control.

• Do not exceed the cargo carrier

capacity.

• Always redu ce speed and allow

greater distance for braking and
turning when carrying cargo or a
passenger, or when towing.

• Always secure cargo before

operating vehicle.

• Overloading or carrying tall, off-

center, or unsecured loads will
increase your risk of losing con­trol. Loads should be centered,
carried as low as possible, and firmly secured to the carrier.

• Be careful if load extends over the side of the carrier.

The maximum weight capacity for the cargo carrier is 75 lbs. (34.1 kg).
Do not allow a passenger to sit on the seat back or in the cargo carrier.

NOTICE: Do not drive aggressively or jump your vehicle when operating with

heavy loads in the cargo carrier. This may cause vehicle damage.

Cargo Carrier

33

FEATURES

Fuel Resistor

This snowmobile is equipped with a feature that allows the engine con­troller to select the proper operating software based on the type of fuel
being used. See pages 62-63 for fuel information and recommendations.

Make sure the correct resistor is installed for your fuel choice as
instructed below.

PREMIUM NON-ETHANOL Resistor

To achieve maximum performance, install this resistor to the ECU fuel
designation connector when using:

• Non-ethanol gasoline with a 91+ octane rating

10% ETHANOL Resistor

This resistor must be installed when using:

Whenever in doubt of your fuel purchase, use the “10% ETHANOL”
resistor as a safeguard.

The resistor is installed into the wiring harness on the left side of the
snowmobile just above the top of the oil bottle. To change resistors,
unplug the resistor and rotate it to align and install the appropriate plug
to the connection.

NOTICE: Engi ne damage may occur if ethanol fuel is used while the non-eth a-

nol fuel resistor is installed. The check engine light may also display in
this condition as this could cause detonation.

• Ethanol gasoline • Other forms of oxygenated gasoline

• MTBE gasoline • Any fuel less than 91 octane

NON-ETHANOL GASOLINE

91+ OCTANE

(Maximum Performance)

ETHANOL, MTBE, OR OTHER

OXYGENATED GASOLINE (Factory Delivery)

ANY FUEL WITH ETHANOL or LESS THAN

91 OCTANE (87 Octane Minimum)

10% ETHANOL

Resistor Installed

34

FEATURES

Detonation Elimination Technology (DET)

The DET system prevents damage to the engine from detonation by
going into an engine protection mode whenever the DET system is
active. When excessive detonation is detected, the check engine light
will illuminate, flicker or flash momentarily..

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.

If severe detonation occurs, the check engine light will begin to flash.
The engine will enter a limp home mode (and RPM will be limited to
6500 RPM) and stay in this mode until the engine is shut down and
restarted.

The most likely causes of severe detonation are shown in the table
below. Refer to the table for troubleshooting information.

DET Troubleshooting

Check Engine Light Status Indicates

Solid or Flickering Detonation detected
Flashing Severe detonation detected, RPM will

be limited

Cause of DET Activation Solution

Poor quality fuel Replace with higher quality fuel
Incorrect ethanol/non-ethanol fuel

resistor installed

V erify correct fuel resistor for fuel type

in tank
Low fuel/no fuel in tank Refuel with recommended fuel
Water in fuel Replace with recommended fuel
Plugged fuel filter or tank pick-up sock See your POLARIS dealer for service
Alcohol-based fuel additive used with

Ethanol fuel

Do not add de-icers or additives that

contain any form of alcohol while

using up to 10% ethanol fuel
Improper engine modifications Do not modify the engine

35

FEATURES

Instrumentation

MFD Component Identification

Digital Display Identification

Item

1 Analog Gauge (if equipped)
2 Digital Gauge
3 Check Engine Indicator
4 High Temp Indicator
5 Brake Indicator
6 Reverse Indicator
7 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 ho ur
KPH - Kilometers per ho ur
RPM -Engine crankshaft

revolutions per

minute

4 Air Temp (if equipped)

Engine Temp
Degrees Celsius
Degrees Fahrenheit

5 Miles/Kilometers
6Hours

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

7 Fuel Level

1

2

3

4

5

6

7

1

2

3

4

5

6

7

36

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.

MFD settings can be made with the
engine running or with the engine
off. If the engine is off, make sure
the stop switch is pressed down, and
turn the ignition key to the START
position briefly to activate the
gauge. The gauge will illuminate for
about 90 seconds.

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

37

FEATURES

Instrumentation

MFD Settings

Speedometer/Tachometer

If your model is equipped with both analog and digital displays, the
speedometer and tachometer can be viewed in either 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

38

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

Press and release the MODE button until the performance program
screen is active. The default display for this screen includes electrical
system voltage (unless equipped with ACE suspension adjustment), fuel
level (if equipped) and either speed or tachometer, whichever is
selected. See page 37.

Press and release the SET button to cycle through the following screens:
odometer, trip 1 odometer, trip 2 odometer, fuel trip odometer (if fuel is
low) 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.

Trip Settings

Trip 1 and T rip 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.

39

FEATURES

Instrumentation

MFD Digital Display Programs

Performance Program

Trip Settings

Trip F automatically displays when the
fuel level is low if the snowmobile is
equipped with an electronic fuel gauge.
The fuel symbol and the last fuel bar on
the MFD gauge (if equipped) will blink
when the fuel level reaches 1/8 of a tank.

The Trip F odometer records distance
traveled, and the fuel symbol continues
to blink, until enough fuel is added to
raise the level above 1/4 of a tank. The
Trip F odometer will automatical ly reset
to zero after refueling.

40

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.

41

FEATURES

Instrumentation

MFD Digital Display Programs

Engine Program

Press and release the MODE button until the engine program screen is
active. The default display for this screen includes engine hours, electri­cal system voltage level, fuel level (if equipped) and either engine cool­ant temperature, air temperature (accessory) or altimeter (accessory).

Press and release the SET button to cycle through the following screens:
hour meter, engine temperature, air temperature (available as an acces­sory), altimeter (available as an accessory) and turbo boost (if
equipped).

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.

42

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.

43

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

Press and release the MODE button until the history program screen is
active. This screen will always display electrical system voltage level
and fuel level (if equipped).

Press and release the SET button to cycle through the Maximum Vehicle
Speed, Maximum Engine RPM and Service Interval Reminder screens.

Maximum Speed/Maximum RPM

The gauge automatically logs the maximum
speed and engine RPM even if the history
program is not active in the display.

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.

44

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.

45

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".

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: T o prevent damage to the lens, do not use alcohol for cleaning. Do not

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

46

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 t he
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

• Toe (ski alignment) (see page 106)

• Camber (see your dealer)

Front Shock Spring Preload

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

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

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

1

2

3

4

47

THE PERFECT FIT

Rear Suspension Adjustments

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

Each rear suspension can be adjusted to suit rider preference and deliver
the best 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.

Make adjustments to one area at a time so you can evaluate the change.
For further assistance, please see your POLARIS 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 sl ide will offer improved performance over a

worn slide. It can also improve top speed.

• 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 80.

48

THE PERFECT FIT

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

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

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

Tip: The rear bumper may need to be raised slightly to fully extend the rear sus-

pension.

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). Adjust sag by rotating the torsion spring
preload cams located on the rear torque arm. See page 49.

The ideal amount of sag for this rear suspension is 2.5 inches (6.4 cm)
(X-Y=2.5 in./6.4 cm).

X

Y

No RiderWith Rider

49

THE PERFECT FIT

Rear Suspension Adjustments

Torsion Spring Preload

To adjust rear torsion spring preload, rotate the three-position cam using
the engine spark plug tool. This adjustment is easier to make if tension
is relieved from the spring. Exercise extreme caution if you use this
method of adjustment, and follow the steps below carefully.

WARNING! A sudden release of tension from a spring could result in serious
injury. Wear eye protection and maintain a firm grip on the spring when
removing and installing it.

1. Grasp the spring firmly with both hands.

2. Maintain a firm grip on the spring and carefully remove the long leg
from the guide block. Be prepared for a sudden release of tension.

3. Carefully allow the leg to unwind and relieve tension from the cam.

4. Rotate the cam to the desired setting.

5. Rewind the long leg of the spring. Mai ntain a firm grip on the spring
while reinstalling it into the guide block.

Tip: Different rate torsion springs may be available if a firmer ride is desired.

Contact your dealer for more information.

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

Soft (long end of cam to front)
Medium (short end of cam up)
Firm (long end of cam up)

Soft Medium Firm

50

THE PERFECT FIT

Rear Suspension Adjustments

Limiter Strap Position (Ski Pressure)

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

High: Limiter strap in high
position

increases ski pressure

Low: Limiter strap in low

position decreases ski pressure

High

Low

51

THE PERFECT FIT

Rear Suspension Adjustments

Shock Compression Valving

The rear track shocks for this model are gas charged shocks. The valv­ing on the gas charged shocks is pre-set.

52

THE PERFECT FIT

Handlebar Adjustments

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

1. Remove the mountain bar.

2. Remove the handlebar cover.

3. Using a 7/16" wrench, loosen
the four nuts on the bottom of
the adjuster block. Turn the
handlebar to the left or right for
access to the back nuts. If nec­essary, pry the blocks apart
with a screwdriver.

4. Adjust the handlebar to the
desired height.

5. Be sure the handlebar, brake
lever and throttle lever operate
smoothly and do not hit the gas
tank, windshield or any other
part of the machine when
turned fully to the left or right.
If necessary, loosen the set
screws for the left and right
controls, rotate the controls
slightly, then tighten the set
screws to the proper torque.

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

could damage the handwarmers.

• Right control torque: 35 in. lbs. (3.95 Nm) +/- 10%.

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

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

7. Reinstall the handlebar cover.

8. Reinstall the mountain bar.

Handlebar

Cover

Adjuster

Block

Bolts

Nuts

Mountain

Bar

53

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.

54

PRE-RIDE INSPECTIONS

Pre-Ride Checklist

Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the refer­enced pages.

Item See Page

Drive Belt Condition 96
Steering System 56
Brake Fluid 57
Brake Lever/Parking Brake Lock 57, 58
Brake System 89
Throttle Lever 55
Throttle Safety Switch 55
Auxiliary Shut-Off Switch (Engine Stop Switch) 61, 70
Ignition Switch 61, 67
Taillight/Brakelight/Headlight 61
Coolant Level 86
Gearcase Oil Level 79
Injection Oil Level 68
Radiator/Cooling Fins (clean and remove any debris) -­Suspension Mounting Bolts 60
Skags (Wear Bars) 60, 107
Ski Saddle and Spindle Bolts 60
Hood Straps/Latches 56
Seat Latches 55
Rear Wheel Idler Bolts 60, 103
Track Alignment/Condition 59, 104
Rail Slide Condition 104

55

PRE-RIDE INSPECTIONS

Before Starting the Engine

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

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

Read and Understand Your Owner's Manual

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

Throttle Lever

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

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

Throttle Safety Switch

T est the throttle safety switch system before the snowmobile is operated.
See page 70 for procedure.

Seat Latch

Check the seat latch before each use of the snowmobile. Push downward
on the seat near the seat latch, then attempt to raise the seat by pulling
upward on the right-hand passenger grab handle. Make sure the latch is
secure before riding.

56

PRE-RIDE INSPECTIONS

Before Starting the Engine

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.

Steering System

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

snowmobile, which could cause loss of control 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 dif ficulty
is encountered, remove ice and snow build-up that may be obstructing
the steering linkage.

57

PRE-RIDE INSPECTIONS

Before Starting the Engine

Brakes

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

Brake Lever Travel

Squeeze the brake lever. It
should move no closer to the
handgrip than 1/2" (1.3 cm).
A smaller distance indicates
low brake fluid level or air in
the hydraulic system. See
pages 89-91 or see your
dealer for service.

Brake Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Check for the presence of air in the fluid system.
See pages 89-91 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.

Brake Fluid

Check the brake fluid in the mas­ter cylinder before each ride.

V iew the brake fluid level through
the sight glass on the top of the
master cylinder. The eye will
appear dark when the fluid level is
full. If the sight glass is any color
other than black, add brake fluid.
See page 90.

1/2" (1.3 cm)

Sight

Glass

Master

Cylinder

58

PRE-RIDE INSPECTIONS

Before Starting the Engine

Parking Brake Lever Lock

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

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.

Brake

Lever

Parking Brake

Lever Lock

59

PRE-RIDE INSPECTIONS

Before Starting the Engine

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.

60

PRE-RIDE INSPECTIONS

Before Starting the Engine

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 103
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 104
Track Tension 102
All rear suspension components Lubrication 81
Ski runner/skag Condition -­Ski spindle bolts Tightness -­Tie rod end nuts Tightness --

61

PRE-RIDE INSPECTIONS

Start the Engine and Check

Engine Stop Switch

Check the auxiliary shut-off switch for proper operation. Push the
switch down to stop the engine. Pull it up to allow restarting.

Ignition Switch

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

Lighting

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

Mirror Adjustment

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

Operating Area

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

62

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 tu rn off the engine befo re 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 refu-

eling 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

63

OPERATION

Fuel Recommendation

For peak performance, POLARIS recommends the use of 91 octane fuel
or higher. 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. Never
use E85 in your snowmobile).

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

damage. Always 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-ethanol fuel (sometimes labeled “non-oxygenated”),
POLARIS recommends the regular use of isopropyl-based fuel system
deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline
to prevent damage resulting from fuel system icing. Never use deicers
or additives containing methanol. POLARIS also recommends the use
of Carbon Clean. See page 116 for the part numbers of POLARIS prod­ucts.

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

64

OPERATION

Break-In Period

Engine Break-In

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

Premix the first tank of fuel as outlined below. Oil added to the fuel and
oil injection systems will provide the necessary engine lubrication.

Tip: The Premium Blue oil will seat the rings faster than the VES oil.

See page 116 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.

Initial Fuel Premix

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

Oil Recommendations

First Tank of Fuel: POLARIS Premium Blue 2-Cycle Oil
After Brea k-in: POLARIS VES 2-Cycle Oil

Fuel Premium Blue Oil Ratio

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

65

OPERATION

Break-In Period

Engine Break-In

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

NOTICE: 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 snow­mobile.

Oil Injection System

Always check and fill the oil bottle when refueling. See page 68.

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

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

Never mix brands of oil. Serious chemical reactions can cause injection
system blockage, resulting in serious engine damage. They 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. See page 64 for oil recommendations.

Drive Belt Break-In

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

New drive belts that feature a sanded finish should be first washed with
warm, soapy water and allowed to air dry prior to use.

Always take time to warm up the belt and driveline prior to operating
the snowmobile. Free the track and skis from the ground before engag­ing throttle.

66

OPERATION

Starting the Engine

1. Turn the key to the ON position.

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.

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

3. Turn the key to START to crank the engine. Release the key to the
ON position when the engine starts. If using the starter rope, grasp
the starter handle and pull slowly until the recoil engages; then pull
abruptly to crank the engine.

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

snap back into the housing. Damage may result.

4. If the engine does not start after several attempts, slightly depress
the throttle no more than 1/4 inch (6 mm) open while cranking the
engine. When the engine starts, immediately release the throttle.

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

NOTICE: Operating the vehicle immediately after cold starting could cause

engine damage. Allow the engine to warm up for several minutes
before operating the vehicle. If cold drive-away is attempted, the
engine RPM may stumble slightly to protect the engine.

67

OPERATION

Restarting an Engine

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

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

2. Turn the key to the OFF position.

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

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

5. Release the throttle.

6. Restart the engine using the normal starting procedure.

Stopping the Snowmobile

The following chart lists methods for stopping the snowmobile. See
page 70 for more information about the engine stop switch.

SYSTEM WHAT IT DOES

THROTTLE

CONDITION

Ignition Switch Interrupts ignition circuit All
Brake Slows jackshaft All
Engine Stop Switch Interrupts ignition circuit All

68

OPERATION

Oil

Low Oil Indicator Light

The low oil indicator light may flicker at times due to oil movement in
the bottle, but when the light comes on and remains on, add the recom­mended oil before further operation.

Visually check the oil level in the bottle. The engine may be operated as
long as oil is visible in the oil tank. If oil is not visible, continued opera­tion may cause serious engine damage.

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.

Always check the oil level when refueling. When the oil reaches the low
level mark, add one quart (.9 liters) of recommended oil to the tank. See
page 64 for oil recommendations.

NOTICE: Operating the snowmobile without adequate engine lubrication can

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

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

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

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

2. Open the left side panel.

3. View the oil level in the oil bottle.

4. Add oil as needed before operating.

NOTICE: Operating the snowmobile without adequate engine lubrication can

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

“Add”

Mark

69

OPERATION

Track Warm-Up

A loose track or flying debris could cause serious injury or death. Stand clear of
the front of the snowmobile and the moving track. Never hold the snowmobile up
or stand behind it while warming up the track. Do not use excessive throttle dur­ing warm-up or when the track is free-hanging. 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

70

OPERATION

Engine Stop Switch

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

Throttle Safety Switch

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

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 dea ler.

Test the throttle safety switch
system daily before operation.

1. Sit on the seat.

2. Start the engine and allow it
to idle.

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

4. Apply a slight amount of throttle. A properly functioning switch

must shut down the engine.

S top Switch

71

OPERATION

Throttle Lever

WARNING! An improperly functioning throttle lever may cause erratic machine

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

If the engine speed limits at 2400 RPM 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.

72

OPERATION

Electronic Reverse (PERCTM)

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 snowmob ile is stopped and when
engine speed is at idle.

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

Engaging Reverse

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

1. Stop the snowmobile and leave the engine idling.

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

3. Push the yellow reverse button on the left-hand control for one sec-

ond, then release. The engine will automatically reduce RPM and
start a reverse rotation. A flashing reverse light on the instrument
panel will indicate that the transmission is in reverse.

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

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

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

restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

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

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

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

ward.

WARNING

73

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

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.

Whenever towing or operating with a heavy load, place the transmission
in low gear. Towing in high gear can result in belt damage. When oper­ating in low gear, vehicle speed will be limited to protect the drive train.

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. Place the
transmission in neutral, and have
someone ride on the towed
snowmobile to operate the brake
and steering when necessary.

NOTICE: T owing a disabled snowmobile with the transmission in gear can result

in serious damage to the engine and drive system. Always place the
transmission of the disabled snowmobile in neutral before towing.

Shifter

74

MAINTENANCE

Emission Control Information

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

Emission Control Label

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

Emission Control Maintenance Requirements

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

Owner's Responsibilities

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

Non-ionizing Radiation

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

75

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 131.

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.

76

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)

95 III

Clutches 95 IIII
Drive Belt 96 CCC
Belt Tension -- IIII
Clutch Sheaves 97 IIII

ENGINE/COOLING

Engine Mounts -- IIII
Recoil Rope -- IIII
Cylinder Head Bolts -- III
Cylinder Base Nuts -- III I
Ignition Timing BTDC -- III
VES System -- CCC I
Coolant Level 86 IIRI
Coolant Hose -- IIII
Coolant Circulation -- III
Coolant Leaks -- IIII
Spark Plugs 82 IIIRI
Exhaust Pipe 85 II
Exhaust Retaining

Springs

85 IIII

77

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 -- IIII
Hose Condition -- IIII
Fluid Leaks -- IIII
Brake Pads 89 IIII
Brake Disc -- IIII
Parking Brakes 58 IIII
Brake System 57, 89 I
Brake Fluid 57 I

FUEL MANAGEMENT

Idle RPM -- III
Throttle Lever 55, 71 III II
Oil Pump Lever

(synchronize)

-- III

Throttle Cable 80 LLL
Throttle Position Sensor -- II I
Fuel Lines 84 III II
Fuel Filter 84 EVERY 2000 (3200) or EVERY 2 YEARS
Oil Filter 85 RR
Oil Lines -- III
Air Box -- III II

ELECTRICAL

Auxiliary Shut-Off
Switch

61 III II

Throttle Safety Switch 70 III II
Ignition Switch -- III II
Taillight 61 III II
Brakelight 61 III II
Headlight 61 III II

78

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 -- III
Suspension Mounting

Bolts

-- III II

Steering Fasteners -- III IC
Rear Suspension

Fasteners

-- III II

Drive Shaft Bearing 80 LLLI
Skags (Wear Bars) 107 III II
Ski Saddle/Spindle Bolts -- III II
Hood Straps 56 III II
Rear Wheel Idler Bolts

and Nuts

103 II I II

Camber Alignment -- III
Handlebar Centering -- I
Track Alignment 104 II I II
Track Tension 102 III II
Front Limiter Strap -- III I I
Rail Slide Condition 102 I
Gearcase Oil 79 IRI RI

79

MAINTENANCE

Lubrication

Gearcase Oil Level

Check the gearcase oil level at the
intervals outlined in the maintenance
charts beginning on page 75.
Change the gearcase oil after the
first 500 miles (800 km), then every
1000 miles (1600 km) or seasonally.

To check the oil level, place the
snowmobile on a level surface. The
oil level should be between the
“safe” marks on the dipstick (1). Do
not overfill.

POLARIS recommends the use of
POLARIS Synthetic Chaincase
Lube. See page 116 for the part
numbers of POLARIS products.

Clean the magnetic plug (2) every
500 miles (800 km) and whenever changing lubricant.

NOTICE: Mixing brands or using non-recommended lubricants could result in

excessive wear to chain, sprockets and bearings. Always use
POLARIS-recommended products for your vehicle.

1

2

80

MAINTENANCE

Lubrication

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.

Coupler Lubrication

Using a needle-point grease
gun, grease the driveshaft cou­pler only. The jackshaft on this
model is a one-piece jackshaft
that requires no lubrication.

x

Driveshaft

Transmission

81

MAINTENANCE

Lubrication

Rear Suspension

Lubricate the suspension pivot shafts with POLARIS All Season Grease
at the intervals outlined in the Periodic Maintenance Table beginning on
page 76 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.

82

MAINTENANCE

Spark P lugs

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 the spec-

ifications section beginning on page 114.

• Use only resistor-type spark plugs.

• Torque spark plugs to 18-20 ft. lbs. (24-27 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.

83

MAINTENANCE

Spark P lugs

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 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
rich fuel mixture.

84

MAINTENANCE

Intake Filters

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

NOTICE: Operating the snowmobile with

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

Fuel Pump

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

Fuel Filter/Fuel Lines

See your POLARIS dealer for replacement of the fuel filter at the inter­vals outlined in the Periodic Maintenance Table beginning on page 76.

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

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

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.

Intake Filter

85

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). Have your
dealer inspect the return check valve as
well.

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 76.

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. Clean the plastic surfaces next to the muffler with aerosol Carbure­tor and Throttle Body Cleaner. See pa ge 1 16 for the part numbers of
POLARIS products.

6. Close the hood.

86

MAINTENANCE

Cooling System

Coolant

The coolant supplied in the system is a 60/40 mixture of ethylene-glycol
and distilled water. This mixture provides protection against freezing.
Contact your dealer if greater protection is required.

Use POLARIS Antifreeze 60/40 Premix. POLARIS Antifreeze is
already premixed and ready to use. Do not dilute with water. Never
exceed a 60% antifreeze/40% water mixture. See page 116 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.

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

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

Coolant Level

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

• Coolant recovery bottle

• Coolant reservoir

• Pressure cap

• Connecting hoses
Always maintain the coolant level at the “COLD FILL” mark on the

coolant recovery bottle (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.

87

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, the
system should be completely drained every two years and a fresh mix­ture of antifreeze and distilled water should be added. Have your
POLARIS dealer perform this service.

88

MAINTENANCE

Cooling System

Bleeding the Cooling System

CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the

cooling system or remove the pressure cap when the engine is warm or hot.

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

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

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

Perform the bleeding procedure when the engine is cold.

1. Position the vehicle so that the top of the tunnel is level. Elevate the
front of the vehicle slightly if necessary.

2. Place the transmission in neutral.

3. Remove the pressure cap and fill the coolant bottle with properly
mixed coolant to the maximum mark.

4. Remove the bleed screw from the water outlet manifold and/or the
thermostat housing. Allow the coolant to bleed through the system
until it runs out the bleed holes. Reinstall the bleed screw into the
manifold.

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

6. Start the engine and run at a fast idle for two to three minutes.
Loosen the bleed screw occasionally to purge any trapped air.

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

8. Feel the heat exchangers under the tunnel. If the system is bled
properly, they'll be warm to the touch. If they're not, repeat step 6.
Lift the front of the machine slightly to assist in the bleeding.

9. Replace the pressure cap and carefully lower the front end of the
machine.

89

MAINTENANCE

Brakes

Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See
page 57.

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

WARNING! Brake failure during operation can result in serious injury or death.
Be sure the brake pads do not drag on the disc and that brake lever travel is not
excessive. Always replace brake pads when the brake pad material becomes
thinner than the backing plate, approximately 1/16" (1.5mm).

Brake Components

• Brake Caliper

• Gearcase

•Brake Disc

• Backing Plate

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

Brake Disc

Backing

Plate

Brake Pad

Material

Gearcase

Brake

Caliper

90

MAINTENANCE

Brakes

Brake Fluid

After opening a bottle of brake fluid, always discard any unused portion. Never
store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly
absorbs moisture from the air. The moisture causes the boiling temperature of
the brake fluid to drop, which can lead to early brake fade and the possibility of
accident or serious injury.

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

NOTICE: Brake fluid will damage decals, paint and some plastics. Always wipe

up spills immediately.

Check the brake fluid in the mas­ter cylinder before each ride.

V iew the brake fluid level through
the sight glass on the top of the
master cylinder. The eye will
appear dark when the fluid level is
full. If the sight glass is any color
other than black, add brake fluid.

1. Position the handlebars so the
master cylinder is level.

2. Remove the master cylinder
cover.

3. Add DOT 4 brake fluid only. Do not overfill. See page 116 for the
part numbers of POLARIS products.

WARNING

Sight

Glass

Master

Cylinder

91

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

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

WARNING! Operating the vehicle with a spongy brake lever can result in loss of
brakes, which could cause an accident and lead to serious injury or death.
Never operate the vehicle with a spongy-feeling brake lever.

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

1. Remove brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX
marks or 1/4"-5/16" (.6-.8 cm) below the lip of the reservoir open­ing. Reinstall the gasket and cover.

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

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

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

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

WARNING! Overfilling the master cylinder leaves no room for fluid expansion
and may cause the brakes to lock, resulting in serious injury or death. Always
add brake fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level.
See page 57.

8. Reinstall the gasket and cover.

92

MAINTENANCE

Lights

Removing Halogen Bulbs

Tip: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a resi-

due, causing a hot spot that will shorten the life of the lamp. If fi ngers do
touch the bulb, clean it with an alcohol-moistened towel.

1. Remove the plenum cov­ering from the headlight
assembly. Lift the rubber
boot to expose the bulb.

2. Push down on the spring
to release it from the
housing.

3. With the wire harness
attached to the bulb,
withdraw the bulb from
the housing.

4. Grasp the bulb by its
metal base and carefully
separate the bulb from
the harness.

Spring

Harness

Bulb

93

MAINTENANCE

Lights

Installing Halogen Bulbs

1. Hold the bulb by its metal base and install it into the wire harness.

2. Insert the bulb into the housing.

3. Connect the spring to the housing.

4. Carefully flip the spring back into the housing, placing it around the
wire harness.

5. Reinstall the plenum covering on the headlight assembly.

6. Adjust headlight aim. See page 30.

Replacing Taillight Bulbs

1. Remove the screws securing the taillight cover and remove the
cover.

2. Remove the taillight lens.

3. Push the bulb in and twist it counterclockwise to remove it.

4. Install the new bulb.

5. Reinstall the taillight lens.

6. Reinstall the taillight cover.

94

MAINTENANCE

Electrical System

RELAY LABEL FUSE LABEL ITEM POWERED

START SOLENOID
RELAY

Ground side of start solenoid

CHASSIS
RELAY

SPARE 20A None
ACCESSORY

EMERGENCY
SPARE 30A

Accessory plugs

CHASSIS
30A

High beams
Low beams
Handwarmers
Thumbwarmer
Passenger handwarmers
Work light
Tail lamp
Brake lamp
Alternator coils

EFI
RELAY

EX. SENSOR
GAUGE 20A

Exhaust sensor
Gauge
Accessory projector beam relay
Diagnostic plug

IGNITION 20A Ignition relay power

EFI
20A

Cam phase sensor
ECU hold-on power
Forward limit switch
Start relay coil
Chassis relay coil
Ignition relay coil
Fuel pump relay coil
Fan relay coil
Fuel pump relay power
PTO injector
MAG injector

IGNITION RELAY PTO ignition coil

MAG ignition coil
FUEL PUMP RELAY Fuel pump
FAN RELAY Radiator fan

95

MAINTENANCE

Clutch System

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

WARNING! If you become aware of higher than normal clutch engagement or
an unusual vibration or shift pattern, see your dealer immediately. Do not
operate the snowmobile until repairs have been made.

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

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

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

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum perfor­mance. Please see your POLARIS dealer if you experience a decrease in
performance.

96

MAINTENANCE

Clutch System

Drive Belt Condition

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

121.
For improved drive-away during extremely cold temperatures, remove

the belt and warm it to room temperature. Reinstall it before starting the
snowmobile.

Drive Belt Deflection

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

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

Straight

Edge

Measure

A

97

MAINTENANCE

Clutch System

Drive Belt Adjustment

1. Install the L-wrench into the open threaded hole in the outer sheave
of the clutch (see page 98). Turn the wrench clockwise slightly to
remove pressure from the sheaves.

2. Loosen the 7/16-inch jam nut.

3. Using a 1/8-inch Allen wrench, aturn the set screw inward (clock-

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

4. Tighten the jam nut. Remove the L-wrench and store it in the tool
kit.

98

MAINTENANCE

Clutch System

Drive Belt Removal

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

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

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

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

3. Lock the parking brake.

4. Open the hood and remove the left side panel.

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

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

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

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

8. Grasp the belt at the lower edge and remove it.