Polaris 600 RMK User Manual

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.

PROPOSITION 65

WARNING

Snowmobile engines discharge fuel

and exhaust, which contain chemicals

known to the State of California to

cause cancer and birth defects or other

reproductive harm, onto the snow on

which they operate. Keep this engine

properly tuned and avoid unnecessary

idling and spillage during fueling.

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.

S Snowmobiles
S All-terrain vehicles (ATVs)
S RANGER utility vehicles
S Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.

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

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

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

1

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

RIDER SELECT is a trademark of Polaris Industries Inc.

Copyright 2005 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

Printed in U.S.A.

2006 600 RMK/Switchback Owner’s Manual P/N 9920058

2

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 25..................................

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

The Perfect Fit 39............................

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

Pre-Ride Inspections 50......................

This section explains procedures that must be performed before riding.

Operation 57.................................

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

Maintenance 70..............................

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

Polaris Products 108.........................

Troubleshooting 109.........................

Warranty 114................................

Maintenance Log 120.........................

Index 122....................................

3

4

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 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.

5

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.

6

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.

L

Vehicle Model Number:

Tunnel VIN (L):

Engine Serial Number (on recoil housing):

Key Number:

7

SAFETY

Operator Safety

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

The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for injury.

WARNING

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

CAUTION

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

CAUTION

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

NOTE:

A note will alert you to important information or instructions.

8

SAFETY

Operator Safety

Follow the recommended maintenance program outlined beginning on
page 70 of this manual to ensure that all critical components on the
snowmobile are thoroughly inspected by your dealer at specific
mileage intervals.

WARNING

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

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

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

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

9

SAFETY

Operator Safety

Stay Clear of Track

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

WARNING

Serious injuries may result if
hands, feet, or clothing become
entangled in the track. Be alert
when riding, and remain properly
seated to stay clear of the track.

Never hold the snowmobile up or
stand behind it while warming up
the track. A loose track or flying
debris could cause serious injury or
death. We recommend having your
dealer perform all track service and
alignment procedures.

Stay Clear of Engine

Never attempt adjustments with the engine running. Turn off the
ignition, raise the hood, make the adjustment, secure shields and
guards, secure the hood, and then restart the engine to check its
operation.

WARNING

Serious injury can occur if fingers or clothing contact the moving
parts of an engine. Always stop the engine before attempting
adjustments.

Riding Position

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

10

SAFETY

Operator Safety

Survival Preparation

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

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

SSpare Drive Belt SExtra Set of Spark Plugs
STow Rope SExtra Oil
SFuel Deicer SWinter Survival Kit
STrail Map SOwner’s Manual
SFirst Aid Kit STool Kit

Riding Apparel

Be prepared, be warm and be
comfortable when riding. Be
aware of the weather
forecast, especially the
windchill, and dress
accordingly. See the chart
on page 20.

WARNING

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

11

SAFETY

Operator Safety

Disabled Operators

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

Rider Capacity

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

Excessive Speed

WARNING

High speed driving, especially at night, could result in serious
injury or death. Always reduce speed when driving at night or in
inclement weather.

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

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

12

SAFETY

Operator Safety

Driver Awareness

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

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

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

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

13

SAFETY

Operator Safety

Avalanches

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

S Take an avalanche class
S Travel with experienced people
S Travel on designated trails
S Make sure each person is equipped with

a shovel, probe and avalanche beacon.

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

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

For more information about avalanche training and avalanche
conditions, contact local law enforcement in your area, or visit either
the American Avalanche Association online at
www.americanavalancheassociation.org or the U.S. Forest Service
National Avalanche Center at www.avalanche.org.

14

SAFETY

Operator Safety

Ice and Snow Build-up

WARNING

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

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

NOTE: If your snowmobile is equipped with RIDER SELECT,

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

Driving on Slippery Surfaces

WARNING

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

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

Driving Downhill

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

WARNING

When driving on long downhill stretches, pump the brakes.
Riding the brakes may cause the brake system to overheat,
which may result in brake failure.

Excessive or repetitive use of the brakes for high speed stops will
also cause an overheated brake system. This condition may lead
to a sudden loss of brakes and/or fire and may result in serious
injury or death.

15

SAFETY

Operator Safety

Driving in Hilly Terrain

WARNING

Climbing a hill or crossing the face of a slope may result in loss of
balance and machine roll-over, causing serious injury or death.
Use caution and good judgement when driving in hilly terrain.

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

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

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

16

SAFETY

Operator Safety

Drive Belt

Do not operate the engine with the drive belt removed.

Any servicing that requires operation without a belt must be performed
by your dealer. Operation of the engine with the belt removed may
result in injury or damage to the engine.

Intake Silencer

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

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

Clutches

Do not attempt to service the clutches.

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

Cold Weather Drive-Away

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

Maneuverability

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

17

SAFETY

Operator Safety

Inadequate Snow Conditions

WARNING

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

Since snow provides the only lubrication for the power slide
suspension and, on liquid cooled models, cooling for the engine,
adequate snow cover is a requirement for operation of your machine.
Driving in too little snow will result in excessive wear and damage to
the slide rail, track and/or engine.

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

CAUTION

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

18

SAFETY

Operator Safety

Driving Responsibly

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

S A snowmobile depends on the rider’s body position for proper bal-

ance in executing turns, traversing hills, etc. Always start on a
smooth, level area to begin building your operating experience.

S Before allowing someone else use your snowmobile, know the ex-

tent 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.

S Don’t “jump” your snowmobile. Jumping may injure your back be-

cause of spinal compression. The seat and suspension of your snow­mobile have been designed to provide protection under normal
riding conditions. Your snowmobile is not intended for this kind of
use.

S Be courteous to oncoming traffic by dimming your headlights and

reducing your speed.

S 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.

S Remove the key from the ignition when you leave the snowmobile

unattended.

19

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WIND CHILL CHART (°F)

Wind

Speed

in

MPH

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

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

5 36 31 25 19 13 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

Frostbitein>> 30 min. 10 min. 5min.

WIND CHILL CHART (°C)

Wind

Speed

in

KPH

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

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

8 3 0 - -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

Frostbitein>> 30 min. 10 min. 5min.

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

Actual Thermometer Reading (°C)

Equivalent Temperature (°C)

20

SAFETY

Safety Decals and Locations

Warning decals have been placed on the snowmobile for your

protection. Read and follow the instructions of the decals and other

warnings on the snowmobile carefully. If any of the decals depicted in

this manual differ from the decals on your snowmobile, always read

and follow the instructions of the decals on the snowmobile.

If any decal becomes illegible or comes off, contact your Polaris dealer

to purchase a replacement. Replacement safety decals are provided by

Polaris at no charge. The part number is printed on the decal.

Clutch Cover Warning

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

Pressure Cap Warning

This warning decal is found under the hood on the pressure cap of

applicable liquid cooled models:

Warming
Do not open hot. Test or replace when changing

coolant. Press down and turn to release cap. 13
PSI

21

SAFETY

Safety Decals and Locations

Track Warning

Warming
Stay clear of track. Do not sit on

seat back. Entanglement with the
track or a fall from seat back may
result in severe injury or death.

“No Passenger” Warning

Warming
This vehicle is designed for

operator only.
“NO PASSENGER”

+

+

22

Safety Decals and Locations

SAFETY

+

+

Reverse Warning

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

S Look behind before and while backing.
S Avoid sharp turns.
S Shift to or from reverse only when stopped.
S Apply throttle slowly.

NOTE: For more information, see Owner’s Manual.
If electric reverse:

S Machine stopped and engine at idle, push yellow button on LH

controlto reverse. Flashinglight on dash indicates reverse opera­tion.

S Push button again to return to forward.
S Elevation setting (above 6000 feet): push and hold for longer than

5 seconds to set. Let go of button at desired setting-fast flash for
high elevation, slower flash for low. Setting will remain until
changed.

23

SAFETY

Safety Decals and Locations

Operation Warning

S To avoid serious injury or death,

read and understand all warnings

and the Owner’s Manual before

operation. If the manual is miss-

ing, contact a Polaris dealer for a

replacement.

S This vehicle is capable of high

speeds. Buried objects or un-

even terrain can cause loss of

control. Reduce speed and use

extreme caution when operating

in unfamiliar terrain.

S 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.

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

S Always wear an approved helmet, eye protection, and adequate clothing

while operating this v ehicle.

S This vehicle is designed for adult use only. Check local laws for age require-

ments.

S 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.

S 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.

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

a proper balance of ski carbides to track studs. See Owner’s Manual for

proper use of traction products.

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

ability.

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

engaged for more than five minutes.

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

tion. Make sure hood is latched. Be seated and in position to control the ve-

hicle.

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

+

+

24

1. Hood

2. Headlight

3. Windshield

4. Handlebar

5. Side Shield

6. Seat

7. Storage Compartment

8. Taillights

2

FEATURES

9. Rear Bumper

10. Snow Flap

11. Suspension

12. Track

13. Nosepan

14. Front Bumper

15. Ski

3

4

6

5

7

8

9

1

15

1. Fuel Filler Cap

2. Rider Selectt

3. Ignition Switch

4. Handlebar hook

5. Brake Lever

6. Mountain Bar

7. MFD (Multi-Function Display)

8. Engine Stop Switch

9. Choke

14

13

6

5

4

7

10

11

12

10. Throttle Control

11. Recoil Starter Handle

12. Hood Hold Down Straps

13. Headlight Dimmer Switch

14. Parking Brake

15. Handlebar Grip Warmer Switch

16. Thumbwarmer Switch

17. Electronic Reverse Button

18. MFD Control

7

8

14

15 16

9

10

17

13

3

2

11

12

18

1

25

FEATURES

RIDER SELECT Adjustable Steering System

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

Choosing the Best RIDER SELECTt Position

Position Riding Style

1

Relaxed Trail Riding

2

Rider weight is slightly behind the center
of the snowmobile for comfortable and re-

3

laxed riding.

45General Trail Riding, Boondocking,

Deep Snow Riding

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

most riding situations.

67Snowcross & Steep Hill Climbing

Only

Rider weight is slightly ahead of the center
of the snowmobile, adding weight to the
skis and making the snowmobile feel
heavier at the front. These positions are
desirable for hill climbing and may reduce
maneuverability for other types of riding.

26

FEATURES

RIDER SELECT Adjustable Steering System

WARNING

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

1. Stop the snowmobile.

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

WARNING

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

WARNING

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

Adjustable Headlights

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

27

FEATURES

Fuel Valve

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

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

2. Turn the valve counter-clockwise
to turn on the fuel supply.

Seat Storage
Compartment

Lift the seat lever (+) and lift the
seat to access the under-seat storage
area.

Radiator Compartment
Access Panel

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

+

1

2

Cargo Rack

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

28

+

+

FEATURES

Detonation Elimination Technology (D.E.T.)

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

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

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

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

DET Troubleshooting

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

Possible Cause Solution

Poor quality fuel Replace with higher quality fuel

Improper engine modifications Do not modify the engine

Improper jetting Use the correct jetting for your altitude

Sensor Fail -Safe

The DET includes a sensor fail-safe system to prevent the engine from
damage if the sensor fails, becomes disconnected or is unable to detect
detonation. The rider will experience a loss in power. The sensor must
be reconnected or repaired to regain full power.

NOTE: The DET light will flash six times if the sensor fails or

becomes disconnected.

29

FEATURES

Instrumentation

MFD Component Identification

Item

1 Analog Gauge

2 Digital Gauge

3 DET Indicator

4 Low Oil Indicator

5 High Temp Indicator

6 Brake Indicator

7 Reverse Indicator

8 High Beam Indicator

1

3

4

Digital Display Identification

Item

1 RPM o r Speed

Altitude (if equipped)
Service Interval

2 Electrical System Voltage

Level

3 MAX - Maximum MPH/

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

revolutions per minute

4 Air Temp (if equipped)

Engine Temp)
Degrees Celsius
Degrees Fahrenheit

5 Miles

Kilometers

6 Hours

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

7 Fuel Level

1

2

8

5

7

6

2

5

4

6

7

3

30

FEATURES

Instrumentation

MFD Settings

With the engine running, use the
MFD Control Switch (1) to set the
MFD display to your preference.
The rocker switch has a MODE
button (2) and a SET button (3).

Standard vs. Metric

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

Speedometer/Tachometer

The speedometer and tachometer can be viewed in either the analog or
the digital display. If the analog display is set to show speedometer
readings, the digital screen will automatically display the tachometer
(option 1). If the analog is set to show the tachometer, the digital
screen will show the speedometer (option 2).

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

1

2

3

Option Analog

Display

1 Speed RPM Blue “mph” Blue

2 RPM Speed Red “X100rpm” Red

Digital

Display

Analog
Screen

Digital

Screen

Backlight

Backlight

31

FEATURES

Instrumentation

MFD Digital Display Programs

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

NOTE: The analog will always display either MPH or engine RPM

Performance Program

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

While in the Performance mode, press the SET button to cycle through
the odometer, Trip 1, Trip 2, Trip F and Clock settings.

Trip Settings

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

1. To reset a trip odometer to zero,

2. Press and hold the SET button for

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

(whichever setting is selected) regardless of the display
program being viewed.

entertheTrip1orTrip2display.

two seconds.

Odometer Setting

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

32

FEATURES

Instrumentation

MFD Digital Display Programs

Performance Program

Clock Setting

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

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

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

4. Set the minutes in the same manner.

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

NOTE: If the MODE button is not pressed within ten seconds, the

Engine Program

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

Air Temperature (if equipped)

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

clock will automatically save the new entry.

33

FEATURES

Instrumentation

MFD Digital Display Programs

Altitude (if equipped)

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

NOTE: Press and hold the MODE switch

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

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

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

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

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

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

4. Press the MODE button to hold the reading at the adjusted value. If
it’s not pressed within five seconds, the gauge will automatically
save the new setting.

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.

34

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

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

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

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

Maximum Speed/RPM Reset

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

NOTE: Due to electrical noise, the

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

35

FEATURES

Instrumentation

MFD Digital Display Programs

Service Interval Reminder

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

To reset the reminder at the existing interval:

1. Enter the service interval screen.

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

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

To reset the reminder at a new interval:

1. Enter the service interval screen.

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

3. Immediately release the button.

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

NOTE: The maximum interval is 250 hours.

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

36

FEATURES

Instrumentation

MFD Battery Replacement

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

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

2. Locate the black battery
compartment (1). It has a red wire
and a brown wire with a white
stripe. It’s located about three
inches down the main harness
from the point where the harness
connects to the MFD.

3. Cut the plastic cable tie (2) from
the outside of the compartment.

3

4. Carefully cut the bottom of the
compartment (opposite the wires)
to separate the heat-sealed seams.
Squeeze the corners of the compartment inward so the battery (3) is
visible.

NOTE: Note the orientation of the battery before removing it. An

incorrectly installed battery will not maintain the clock.

1

2

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

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

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

6. Install a new battery with fingers only.

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

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

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

37

FEATURES

Instrumentation

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.

CAUTION

To prevent damage to the lens, do not use alcohol for cleaning.
Do not allow chemicals or sprays to come into contact with the
lens. Immediately clean off any gasoline that splashes on the
gauge during refueling.

38

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

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. A-arms

IFS Adjustment Options

S Front shock spring preload
S Optional springs
S Optional shock valving (if

equipped with RydeFX
shocks)

1

2

3

4

39

THE PERFECT FIT

IQ Front Suspension Adjustments

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 upper spring
retainer to fall off.

Shock Valving

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

WARNING

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

Front Springs

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

40

THE PERFECT FIT

Rear Suspension Adjustments

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

Each rear suspension can be adjusted to suit rider preference and
deliver excellent performance for a given set of conditions. However,
all suspension designs and adjustments involve a compromise, or
trade-off. For example, a suspension set up for snow-cross racing
would provide a very stiff ride on the trail. A suspension set up for
trail riding would bottom out harshly on a snow-cross course.

Make adjustments to one area at a time so you can evaluate the change.
For further assistance, see your dealer.

Suspension Performance Tips

S 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.

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

a worn slide. It can also improve top speed.

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

your dealer for assistance.

NOTE: Keep the suspension pivot points lubricated. This will reduce

moisture and rust build-up and ensure proper function of the
suspension components. Grease rear suspension pivots
before adjusting the rear suspension. Refer to Suspension
Maintenance beginning on page 104.

41

THE PERFECT FIT

Rear Suspension Adjustments

Rear Suspension 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 this measurement with no rider
and with the rear suspension at full
extension.

NOTE: The rear bumper may

need to be lifted upward
slightly to fully extend the
suspension.

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

To determine sag, commonly
referred to as ride-in, subtract
measurement Y from X (Sag=X-Y). Adjust sag by rotating the torsion
spring preload cams located on the rear torque arm. See illustration.
The ideal amount of sag for the IQ rear suspension is five inches
(X-Y=5).

If the rear suspension rides in less than four inches or more than six
inches with the torsion spring preload cams at their maximum range of
adjustment, optional torsion springs (softer or stiffer, respectively) may
be required. This is only an initial setup, and final spring preload may
vary based on rider preference and riding conditions.

42

THE PERFECT FIT

Rear Suspension Adjustments

Rear Torsion Spring Tension

To adjust rear torsion spring tension, rotate the three-position cam
using the engine spark plug tool.

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

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

3a

2a

2b

1

3b

4a

4b

1 - Turn screw clockwise to stiffen compression (Standard)
2a - Limiter strap in high position increases ski pressure
2b - Limiter strap in low position decreases ski pressure
3a - Turn the knob to the left for a softer ride (Premium)
3b - Turn the knob to the right for a stiffer ride (Premium)
4a - Soft Tension - long end of cam to front
4b - Medium tension - short end of cam up
4c - Firm tension - long end of cam up

4c

43

THE PERFECT FIT

Rear Suspension Adjustments

Rear Shocks

Indy Select Rear Shock

Some snowmobiles are equipped with the Indy Select rear shock,
which allows for adjustments to the compression valving by turning
the adjustment screw located near the base of the shock.

Locate the adjustment screw (L) near the base of the shock. In
half-turn increments, turn the screw clockwise to increase compression
valving and stiffen the ride, or counterclockwise to reduce compression
and soften the ride. There are approximately three full turns of
adjustment available.

If bottoming continues after the screw has been turned fully clockwise,
the torsion spring should be adjusted (see page 43). Return the screw
to its original starting position after the torsion spring has been
adjusted.

L

44

THE PERFECT FIT

Rear Suspension Adjustments

Rear Shocks

ARVIN Rapid Adjust Shock

The ARVIN Rapid Adjust shock is available as an option on some
models. Turn the Rapid Adjust knob (L) on the shock reservoir to
make adjustments to the compression damping.

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

L

45

THE PERFECT FIT

Handlebar Adjustments

Handlebar Position

Use the RIDER SELECT feature to adjust handlebar position. See
page 26.

Handlebar Angle

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

1. Remove the handlebar cover (1)
to expose the handlebar and the
four adjuster block bolts (2).

NOTE: If necessary, remove the

mountain bar (3).

2. Using a 7/16″ (11 mm) wrench,
loosen the four nuts (3) on the
bottom of the adjuster block (turn
handlebar to left or right for
access to back nuts).

NOTE: If necessary, pry the

blocks apart with a
screwdriver.

1

2

4

3

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

4. Torque the handlebar adjuster block bolts to 11-13 ft. lbs. (15-18
Nm).

NOTE: Torque the front bolts first.

5. Reinstall the handlebar cover.

46

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:

S Non-compliance with government/industry requirements
S Voiding of warranty
S Injury to self or others

This applies, but is not limited to the following areas: brakes, clutches,
fuel systems, and exhaust systems.

NOTE: Exhaust systems are critical safety areas that must use

approved Polaris parts. Please see your Polaris dealer for
service.

47

THE PERFECT FIT

Traction Products (SwitchBack only)

Studs

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

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

See your dealer about installing studs and/or carbides.

CAUTION

Always install wear strips before installing studs. Failure to install
wear strips may result in cooler or tunnel damage. See page 49.

Never add shims to the wear strip. Track damage will result
because of lack of clearance between upper carrier wheels and
track.

Use of studs longer than the recommended length on machines
equipped with center coolers will result in center cooler damage
or damage to the tunnel.

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

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

CAUTION

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

48

THE PERFECT FIT

Traction Products (SwitchBack only)

n

Carbide Skags

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

103.
If your machine has carbide skags, it may be necessary to add track

studs to maintain proper vehicle control. Maintain a proper balance
between the number of studs and the length of carbide on the skags
(the more studs you use, the longer the carbide on the skags should be).
See your dealer’s track studding chart.

Wear Strips

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

Install Wear Strip Kit P/N 2875415.

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

CAUTION

Whenever wear strips are relocated, be sure there’s adequate
stud clearance to the heat exchangers. Lack of clearance may
result in damage to heat exchangers.

49

PRE-RIDE INSPECTIONS

SeeP

Pre-Ride Checklist

Inspect all items on the checklist for proper operation or condition
before each use of the snowmobile. Procedures are outlined on the
referenced pages. Look for a checkmark (n) on the referenced pages
to locate the pre-ride inspection items.

Item

Drive Belt Condition 93, 95

Steering System 52

Recoil Rope 52

Coolant Level 84

Park Brake Lock/Brake Lever/Brake System 53, 54, 88

Auxiliary Shut-Off Switch (Engine Stop Switch) 56

Ignition Switch 56

Taillight/Brakelight/Headlight 56

Suspension Mounting Bolts 105

Skags (Wear Bars) 49, 103

Ski Saddle and Spindle Bolts 104

Hood Straps/Latches 52

Seat Latches 51

Throttle Lever/Safety Switch 51, 64, 65

Rear Wheel Idler Bolts 99, 104

Tether Switch/Strap 56

Track Alignment/Condition 55, 100

Rail Slide Condition 104

Chaincase Oil Level 76

Injection Oil Level 63

age

50

PRE-RIDE INSPECTIONS

Before Starting the Engine

WARNING

Worn, damaged, or malfunctioning components may cause
serious injury or death. Before starting the engine, check all
components to be sure of proper operation.

Read and Understand Your Owner’s Manual

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

n T h rottle Lever

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

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

n T h rottle Safety Switch

Test the throttle safety switch system before the machine is operated.
See page 64 for procedure.

n Seat Latches

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

51

PRE-RIDE INSPECTIONS

Before Starting the Engine

n

Hood Latches

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

n Recoil Rope

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

n Steering System

WARNING

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

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

NOTE: If your snowmobile is equipped with RIDER SELECT,

52

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

PRE-RIDE INSPECTIONS

Before Starting the Engine

n

Brakes

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

Brake Lever Travel

Squeeze the brake lever.
It should move no closer
to the handgrip than 1/2″ (1.3 cm).
A smaller distance indicates low brake fluid level or air in the
hydraulic system. Refer to the brake bleeding information on page 90.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 89.

Check for the presence of air in the fluid system. See page 90 for more
information, or see your dealer for service.

1/2″
(1.3 cm)

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.

53

PRE-RIDE INSPECTIONS

Before Starting the Engine

n

Park Brake L ever Lock

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

1. Brake Lever

2. Park Brake Lever Lock

3. Master Cylinder Reservoir /
Cover

4. Fluid Level Indicator

Lock Engagement

To engage the lock, squeeze the
brake lever tightly and push
forwardonthelock. Holdthe
lock forward while releasing the
brake lever.

NOTE: If the brake lever is squeezed tightly enough, the lock will

move freely into place. Do not force the lock or it may break.

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

Lock Release

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

2

1

3

4

WARNING

If the park 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.

54

PRE-RIDE INSPECTIONS

Before Starting the Engine

n

Track

WARNING

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

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

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

Deep Lug Tracks (if equipped)

The 2.4” powder track is designed specifically for deep snow
applications. Operation in low snow conditions at high speeds may
cause track lug separation. Track lug separation is not covered under
the Polaris limited warranty policy. Polaris does not recommend

operation above 70 mph with this track.

lubrication conditions voids the track warranty.

CAUTION

High speed use on hardpacked surfaces is not recommended for
models equipped with a deep lug track. Track lug damage may
occur. Keep high speed use to a minimum, including frequent
slow-speed intervals for track cooling.

55

PRE-RIDE INSPECTIONS

Start the Engine and Check

n Engine Stop Switch

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

n Ignition Switch

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

n Tether Switch

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

n Lighting
Check the headlight (high and low beam), taillight, and brake light.

Replace burned out lamps before operating.

n Mirror Adjustment

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

n Operating Area

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

56

OPERATION

Starting the Engine

WARNING

Before starting the engine, always refer to all safety warnings
pertaining to snowmobile operation. Never start your snowmobile
without checking all components to be sure of proper operation.
See Check Before Starting the Engine beginning on page 51.

Starting a Cold Engine

Do not depress the throttle
until the engine starts.

1. Turn the fuel valve on.
Seepage28.

2. Turn the key to the ON
position.

3. Pull the engine stop
switchuptotheRUN
position.

4. Flip the choke toggle to
FULL ON.

5. Grasp the recoil rope
handle and pull slowly
until the recoil engages;
then pull abruptly.

6. Repeat as needed until the
engine starts.

CHOKE TOGGLE POSITIONS

OFF

HALF ON

FULL ON

CAUTION

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

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

7. After the engine starts, flip the choke toggle to the OFF position.
If the engine slows or wants to stop, use intermittent choking to the
HALF ON position.

57

OPERATION

Starting the Engine

Starting a Warm Engine

1. Turn the key to the ON position.

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

3. Grasp the recoil rope handle and pull slowly until the recoil
engages; then pull abruptly.

NOTE: If the engine does not start on the first pull, slightly depress

the throttle with your left hand (no more than 1/4” open), and
pull the rope with your right hand. When the engine starts,
immediately release the throttle.

Engine Break-In

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

CAUTION

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

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

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

58

OPERATION

Engine Break-In

Oil Injection System

Always fill the oil tank when refueling. See page 63.

CAUTION

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

Oil Recommendations

This snowmobile is equipped with a variable exhaust system (VES).
Engine lubrication comes from oil added to the fuel and oil injection
systems. Polaris recommends the use of VES II 2 Cycle Oil for this
engine. See page 108 for the part numbers of Polaris products.

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

Slide Rail and Track Cooling

CAUTION

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

CAUTION

High speed use on hardpacked surfaces is not recommended for
models equipped with a deep lug track. Track lug damage may
occur. Keep high speed use to a minimum, including frequent
slow-speed intervals for track cooling.

59

OPERATION

Track Warm-Up

WARNING

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

WARNING

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

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

1. Use an appropriate stand to

securely support the rear of
the snowmobile at the rear
bumper. The track should be
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.

NOTE: It will take longer to warm up the track sufficiently during

colder outdoor temperatures.

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

the machine to the ground.

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

to loosen snow and ice.

60

OPERATION

Fuel

WARNING

Gasoline is highly flammable and explosive under certain
conditions.

S Always exercise extreme caution whenever handling gasoline.
S Always refuel outdoors or in a well-ventilated area.
S Always turn off the engine before refueling.
S Do not overfill the tank. Do not fill the tank neck.
S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

S If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing.

S 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.

S Turn the fuel valve off whenever the snowmobile is stored or

parked.

WARNING

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

61

OPERATION

Fuel

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

CAUTION

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

Damage to the fuel pump will occur if the snowmobile is operated
with an empty fuel tank. Do not allow the snowmobile to run out
of fuel. Always refuel when the level is low.

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

Fuel Level

The fuel symbol and the last fuel bar on the MFD gauge will blink
when the fuel level reaches 1/8th tank. There will be approximately
one gallon of fuel remaining. Refuel as soon as possible. Do not allow

the snowmobile to run out of fuel.

Fuel System Deicers

If you use non-oxygenated fuel, Polaris recommends the regular use of
isopropyl-based fuel system deicer. Add one to two ounces per gallon
(8-16 ml per liter) of gasoline to prevent engine damage resulting from
fuel system icing and lean fuel mixtures. Never use deicers or
additives containing methanol. Polaris also recommends the use of
Carbon Clean Plus. See page 108 for the part numbers of Polaris
products.

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

62

OPERATION

Oil

n

Low Oil Indicator Light

The low oil indicator light will alert the operator if the oil level is low.
Visually check the oil level in the bottle. Add oil before further
operation of the snowmobile. See page 59 for oil recommendations.

n Low Oil Level

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

CAUTION

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

Always maintain a visible level of oil in the tank. If oil is not visible,
continued operation may cause serious engine damage. See page 71
for oil recommendations.

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

63

OPERATION

n Engine Stop Switch

Push down on the engine stop
switch (L) to ground out the
ignition and stop the engine
quickly. Pull the switch up to the
ON position to allow restarting.

n Throttle Safety Switch

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

L

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 throttle
system malfunction, immediately push down the engine stop
switch. Do not start the engine again until the malfunction has
been corrected by your dealer.

Test the throttle safety switch
system daily before operation.

1. Sit on the seat.

2. Start the engine and allow it to

idle.

3. Hold the throttle lever pin

stationary by exerting pressure
on the pivot pin in the direction
shown in the illustration (L).

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

must shut down the engine.

L

64

OPERATION

Throttle Lever

WARNING

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

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

1. Turn the ignition switch to OFF.

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

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

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

5. If the engine doesn’t start, take the snowmobile to an authorized
Polaris dealer for service.

Excessive freeplay in the throttle cable may cause the safety switch to
activate, preventing the engine from starting. If this occurs, return the
machine to an authorized Polaris dealer for service.

If an emergency exists and it’s necessary to start the engine, the throttle
safety switch and engine stop switch may be disconnected from the
wire harness. When these switches are disconnected, the ignition key
switch must be used to shut off the engine. DO NOT continue to
operate the machine with the throttle safety switch disconnected.
Return the machine to an authorized Polaris dealer for service as soon
as possible.

65

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 64 for more information about the
engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES THROTTLE

CONDITION

Ignition Switch Interrupts ignition circuit All

Brake Slows jackshaft All

Choke Floods engine Half throttle or less

Engine Stop Switch Interrupts ignition circuit All

Throttle Safety Switch Interrupts ignition circuit All

Tether Switch (Option) Interrupts ignition circuit All

66

OPERATION

Emergency Starting

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

1. Open the hood.

2. Remove the left side panel.

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

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

WARNING

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

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

6. Reinstall the side panel.

7. Close and secure the hood.

67

OPERATION

Electronic Reverse (PERCt)

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

WARNING

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

S Shift to or from reverse only when the snowmobile is stopped

and when engine speed is at idle.

S Look behind the vehicle before and while backing.
S Avoid sharp turns.
S Apply throttle slowly .

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

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

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

NOTE: If the engine stops running, the snowmobile will be in forward

gear when it’s restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

68

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
machine.

Towing

WARNING

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

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

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

CAUTION

Towing a disabled snowmobile with the drive belt in place can
result in serious damage to the engine and drive system. Always
remove the drive belt from a disabled snowmobile before towing.

69

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 120.

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

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

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

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

CAUTION

Hot components can cause damage to plastic. Always make
sure the exhaust system and engine have cooled before tipping
the snowmobile on its side for service or inspection.

70

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.

See

Item

Clutch Offset Alignment
(without belt)

Drive Belt Condition 93 I I I I

Clutches (disassemble) 92 C C C

Belt Tension - I I I I

Clutch Sheaves 92 I I I I

Engine Mounts - I I I I

Recoil Rope - I I I I

Engine Mounting Plate - I I I

Engine Torque Stop 95 I I I I

Cylinder Head Bolts - I I I

Cylinder Base Nuts - I I I I

Ignition Timing BTDC - I I I

VES System - C C C I

Coolant Level 84 I I R I

Water Pump Drive Belt - I I I

Coolant Hose - I I I I

Heat Exchangers - I I I I I

Coolant Circulation - I I I

Coolant Leaks - I I I I

Spark Plug Condition 79 I I I I I

Exhaust Pipe 81 I I

Exhaust Retaining
Springs

Page

150 mi.

(240 km)

92

81 I I I I

(800 km)

Clutch

Engine

Frequency

500 mi.

1000 mi.

(1600 km)

I I I

2000 mi.

(3200 km)

Season

Pre-

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

71

MAINTENANCE

Periodic Maintenance Interval Table

See

Item

Hose Routing - I I I I

Hose Condition - I I I I

Fluid Leaks - I I I I

Brake Pads 88 I I I I

Brake Disc - I I I I

Parking Brakes 54 I I I I

Brake System 51, 88 I

Brake fluid 89 R

Idle RPM - I I I

Throttle Lever 51, 65 I I I I I

Oil Pump Lever
(synchronize)

Throttle Cable 75 L L L

Choke 75 I I I I I

Vent Lines - I I I I

Throttle Position Sensor - I I I

Fuel Filter 80 R R

Fuel Lines - I I I I I

Oil Filter 81 R R

Oil Lines 81 I I I

Air Box/Plenum - I I I I I

Auxiliary Shut-Off Switch 56 I I I I I

Throttle Safety Switch 51, 64 I I I I I

Ignition Switch - I I I I I

Taillight 56 I I I I I

Brakelight 56 I I I I I

Headlight 56 I I I I I

Page

150 mi.

(240 km)

Fuel Management

-

Electrical

(800 km)

Brakes

Frequency

500 mi.

1000 mi.

(1600 km)

I I I

2000 mi.

(3200 km)

Pre-

Season

72

MAINTENANCE

Periodic Maintenance Interval Table

See

Item

Ski Toe Alignment - I I I

Suspension
Mounting Bolts

Steering Fasteners - I I I I C

Rear Suspension
Fasteners

Suspension Shock Oil - I I I I

Cooling Fins and Shroud - I I I I

Drive Shaft Bearings 107 L L L I

Jackshaft Bearings 106 L L L I

Skags (Wear Bars) - I I I I I

Ski Saddle/Spindle Bolts - I I I I I

Drive Chain T ension 87 I I I I I

Hood Straps 52 I I I I I

Rear Wheel Idler Bolts 99 I I I I I

Idler Bolt Jam Nut 99 I I I I I

Rear Suspension Pivot
Shafts

Camber Alignment - I I I

Handlebar Centering - I

Tether Switch and Strap 56 I I I I I

Track Alignment 100 I I I I I

Track Tension 98 I I I I I

Front Limiter Strap - I I I I I

Rail Slide Condition 104 I

Chaincase Oil 76 I I I R I

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

Page

-

-

74

150 mi.

(240 km)

CHASSIS

(800 km)

I I I I I

I I I I I

Frequency

500 mi.

1000 mi.

(1600 km)

L L L

2000 mi.

(3200 km)

Pre-

Season

73

MAINTENANCE

Lubrication

Front Suspension

The front suspension and steering components do not require
lubrication.

Rear Suspension

Lubricate the suspension pivot shafts with Polaris Premium All Season
Grease at 500 miles (800 km) initially, every 1000 miles (1600 km)
after that, and before off-season storage each year. Lack of lubrication
will adversely affect your ride and the life of the suspension. For more
information about suspension lubrication and adjustments, see your
Polaris dealer.

L

L

74

L

L

L

Lubrication

Driveshaft Bearing

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

Throttle Cable

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

Choke and Cable

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

MAINTENANCE

+

+

+

75

MAINTENANCE

Lubrication

n

Chaincase Oil

Check the chaincase oil level at the
intervals outlined in the
maintenance charts beginning on
page 71. The sight glass (1) is
located on the lower rear of the
chaincase. Maintain the oil level at
or slightly below the center of the
sight glass (2). Change the
chaincase oil after the first 500
miles (800 km), then every 1000
miles (1600 km) or seasonally.

Polaris recommends the use of
Polaris Synthetic Chaincase Lube.
See page 108 for the part numbers of
Polaris products.

3

1

Oil Check

1. Position the machine on a level surface.

2. View the oil level at the sight glass.

3. Remove the fill plug (3) and add the recommended oil as needed.
Do not overfill.

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

2

76

MAINTENANCE

Lubrication

Chaincase Oil

Oil Change

1. Position the vehicle on a level
surface.

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

3. Install a new sealing washer on
the drain plug.

NOTE: The sealing surfaces on the drain plug and the oil tank

should be clean and free of burrs, nicks or scratches.

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

5. Remove the fill plug.

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

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

4

77

MAINTENANCE

General Maintenance

Spark Plugs

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

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

CAUTION

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

S Use recommended spark plugs with the proper gap.
S Use only resistor-type spark plugs.
S Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).
S Always carry spare spark plugs.

78

MAINTENANCE

General Maintenance

Spark Plugs

Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed
up and the vehicle has been driven at higher speeds. Immediately
check the spark plug for correct color.

WARNING

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

1. Normal

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

NOTE: The tip should not be white. A white insulator tip indicates

2. Wet Fouled

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

overheating, caused by use of an improper spark plug or
incorrect throttle body adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

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

3. Reverse the procedure for spark plug
installation.

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

5. Reinstall the spark plug cap.

2

79

MAINTENANCE

General Maintenance

Intake Filters

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

+

CAUTION

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

Fuel Pump

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

Fuel Filter/Fuel Lines

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

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

CAUTION

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

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MAINTENANCE

General Maintenance

Oil Filter/Oil Lines

Inspect oil line condition at 1000
miles (1600 km). The oil filter should
be changed annually or every 1000
miles (1600 km). The oil filter is
located on the left side of the bulkhead
behind the drive clutch.

Have your dealer perform the filter change
and bleeding operation.

NOTE: The direction of the arrows indicates the direction of flow

through the filter.

Exhaust System

Check the exhaust system for wear or damage at approximately 2000
miles (3200 km). To inspect, allow the engine and exhaust system to
cool completely. Open the hood and inspect the muffler and pipes for
cracks or damage. Check for weak or missing retaining springs or
damper/support grommets.

WARNING

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

81

MAINTENANCE

General Maintenance

Carburetor

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

CAUTION

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

Carburetor Adjustments

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

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

S Hard starting
S Poor idle
S Overheated pistons and cylinder walls
S Plug fouling
S Poor engine response to various throttle valve openings

82

MAINTENANCE

General Maintenance

Carburetor Water/Sediment Trap

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

WARNING

When draining the traps, fuel spillage will occur. Always work in a
well ventilated area away from anything that may cause the fuel
to ignite, such as open flames, sparks, heaters, trouble lights,
cigarettes, etc. Review the fuel warnings on page 61.

Cleaning Procedure

1. Turn the fuel valve off. See

page 28.

2. Place a container or shop towels

below the plug to catch drained
fuel.

3. Slide the clamp (1) away from

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

4. Wipe residue from the plug and

reinstall it. Reposition and
tighten the clamp.

5. Repeat the draining procedure

for any remaining traps.

1

2

83

MAINTENANCE

General Maintenance

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 Premium 60/40 anti-freeze coolant, which is already premixed and
ready to use. Do not dilute with water. Never exceed a 60%
antifreeze/40% water mixture. See page 108 for the part numbers of
Polaris products.

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

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

n Coo lan t Level

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

S Coolant bottle or overflow tank
S Engine filler neck
S Pressure cap
S Connecting hoses

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

CAUTION

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

84

MAINTENANCE

General Maintenance

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.

NOTE: Engine performance will be reduced if you continue operating

when the high temperature light is on.

Flushing the Cooling System

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

85

MAINTENANCE

General Maintenance

Bleeding the 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.

WARNING

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

CAUTION

If coolant flow becomes restricted 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.

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

2. Elevate the front end of the machine slightly to aid in bleeding of
the heat exchangers.

3. 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.

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

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

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

7. Feel the heat exchangers under the running boards. If the system is
bled properly, they’ll be warm to the touch. If they’re not, repeat
step 5. Lift the front of the machine slightly to assist in the
bleeding.

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

86

General Maintenance

Drive Chain Tension

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

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

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

3. Finger tighten the adjuster bolt (2)
until it can no longer be adjusted
by hand, then back off 1/4 turn.

4. Tighten the jam nut while
holding the adjuster bolt.
Torque to 21 ft. lbs. (28 Nm).

5. Release the brake lever lock.

MAINTENANCE

2

1

87

MAINTENANCE

General Maintenance

n

Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See
page 53.

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

WARNING

Brake failure during operation can result in serious injury or
death. Properly functioning brakes are vital to your safety. Be
sure the brake pads do not drag on the disc and that brake lever
travel is not excessive.

Always replace brake pads when the brake pad material
becomes thinner than the backing plate (approximately 1/16″).

Brake Components

1. Brake Caliper

2. Brake Disc

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

Excessive Lever Travel

Hydraulic brakes are
self-adjusting, but if excessive
brake pad clearance develops
(see page 88), bring the
machine to an authorized
Polaris dealer for inspection
and adjustment.

3

1

2

88

MAINTENANCE

General Maintenance

Brake Fluid

WARNING

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

WARNING

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

CAUTION

Brake fluid will damage decals, paint and some plastics. Always
wipe up spills immediately.

Replace brake fluid at least every two years with Polaris DOT 4 high
temperature brake fluid. See page 108 for the part numbers of Polaris
products.

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

89

MAINTENANCE

General Maintenance

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.
Seepage89.

8. Reinstall the gasket and cover.

90

General Maintenance

Removing Halogen Bulbs

MAINTENANCE

NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin

1. Remove the plenum covering

2. Lift the rubber boot to expose

3. Push down on the spring (1)

4. With the wire harness (2) attached

5. Grasp the bulb by its metal base and carefully separate the bulb

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

from the headlight assembly.

the bulb.

to release it from the housing.

to the bulb (3), withdraw the bulb from the housing.

from the harness.

2

1

3

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. Verify headlight aim.

Replacing Taillight Bulbs

1. Remove the screws securing the taillight lens.

2. Push the bulb in and twist counterclockwise and replace the bulb.

3. Replace the taillight lens.

91

MAINTENANCE

General 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 machine until repairs have been made.

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

CAUTION

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 and Offset

Clutch alignment offset is important for maintaining optimum
performance. See your dealer for service and adjustments. A special
tool is required to check for proper alignment.

Clutch Center Distance

See your Owner’s Manual Supplement for recommended center
distance for your machine. If adjustment is necessary, see your dealer.

92

MAINTENANCE

General Maintenance

n

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 113.

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 Removal

CAUTION

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.

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.

5. Remove the left side
panel.

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.

+

93

MAINTENANCE

General Maintenance

Drive Belt Installation

1. Drop the drive belt over the
drive clutch and pull back the
slack.

NOTE: To ensure satisfactory belt

life, install belts so they
operate in the same
direction of rotation by
positioning the
identification numbers so
that you can read them. If
required, separate the
sheaves as outlined in the
belt removal procedures.

2. Rotate the L-wrench counter-clockwise to tighten the sheaves
while working the belt to the outer edge of the sheaves.

3. Remove the wrench and store it in the tool kit.

4. Reinstall the side panel.

5. Close and secure the hood.

94

MAINTENANCE

General Maintenance

n

Drive Belt Deflection

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

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

B

Drive Belt Adjustment

TEAM Clutch

1. Loosen the 7/16” jam nut on the belt width adjuster.

2. Using a 1/8” Allen wrench, adjust the threaded set screw as
needed.

NOTE: Turn the set screw in (clockwise) to increase the distance

between the sheaves and out (counterclockwise) to decrease
the distance.

3. Tighten the jam nut.

Torque Stop

Periodically check torque stop clearance. With clutches in proper
alignment, the clearance should be a minimum of .010″ to a maximum
of .030″ from the engine case. Adjust if necessary. Lock the jam nut.

A

.010″-.030″
(.25-.75mm)

95

MAINTENANCE

General Maintenance

Tool Kit

A tool kit is included with
each machine for emergency
and routine maintenance.
Always keep the tool kit with
the snowmobile.

1. Emergency Start Strap

2. L-Wrench

3. Spark Plug
Wrench/Screwdriver

4. Scissor Stop Wrench

5. Combination Wrench

6. Open End Wrench

Fall Tune-Up

For maximum performance, arrange for a fall service tune-up with your
Polaris dealer.

1

2

3

5

4

6

96

MAINTENANCE

Track Maintenance

Track Inspection

WARNING

Broken track rods are a serious safety hazard. They can cause a
rotating track to come off the machine, which could cause serious
injury or death. Never operate with a damaged track. Never
rotate a damaged track under power.

1. Using a hoist, safely lift and
support the rear of the snowmobile
off the ground.

2. Rotate the track by hand to check
for damage.

3. Carefully examine the track along
the entire length of each rod (L).
Bend the track to check for
breakage.

4. Replace the track if any rod
damage is found.

L

Track Lubrication

WARNING

Operating with insufficient lubrication between the rail slide and
track guide clips can cause track failure, loss of vehicle control
and loss of braking ability, which can result in serious injury or
death.

Avoid operating for extended periods on ice and other surfaces
that have little or no snow for lubrication.

The slide rail requires adequate snow cover for sufficient lubrication.
Excessive wear indicates insufficient lubrication. A new rail slide can
cause faster heat build-up in limited lubrication, resulting in excessive
wear.

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

other poor lubrication conditions will void the track warranty.

CAUTION

High speed use on hardpacked surfaces is not recommended for
models equipped with a deep lug track. Track lug damage may
occur. Keep high speed use to a minimum, including frequent
slow-speed intervals for track cooling.

97