Polaris 600 RMK Shift, 700 RMK 155, 800 RMK Shift 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.

WARNING

The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-

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

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

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

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

1

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

Copyright 2008 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies may result between the actual vehicle and the information presented in this publi­cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

Printed in U.S.A.
2009 Owner’s Manual P/N 9921613
600/800 RMK SHIFT-700/800 RMK 155-800 DRAGON RMK-800 ASSAULT RMK

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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 . . . . . . . . . . . . . . . . . . . . 49

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

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

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 110

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 111

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 125

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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 the snowmobile is
sold.

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

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

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

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

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

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.

6

INTRODUCTION

VIN

Vehicle Identification Numbers

Record your snowmobile’s identification numbers and key number in
the spaces provided below. The key number is stamped on the spare key.
The number on the rubber-coated key is in the form of raised dots.
Remove the spare key and store it in a safe place. An ignition key can be
duplicated only by ordering a Polaris key blank (using your key num­ber) and mating it with one of your existing keys. The ignition switch
must be replaced if all keys are lost.

Vehicle Model Number: ___________________________________________________

Tunnel VIN: _____________________________________________________________
(lower right side of the tunnel)

Engine Serial Number (on valve cover): _______________________________________

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, indicates the potential
for serious injury.

WARNING

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

CAUTION

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

NOTICE

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

8

SAFETY

Operator Safety

Follow the recommended maintenance program outlined beginning on
page 71 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.

10

SAFETY

Operator Safety

Riding Position

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

WARNING

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

Survival Preparation

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

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

• Spare Drive Belt • Winter Survival Kit

• Extra Set of Spark Plugs • Trail Map

•Tow Rope •First Aid Kit

• Extra Oil • Tool Kit

• Fuel Deicer

11

SAFETY

E

4

051039

0006.31

Operator Safety

Riding Apparel

Helmet

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

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

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

Eye Protection

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

Clothing

Be prepared, be warm and be com­fortable when riding. Be aware of
the weather forecast, especially the
windchill, and dress accordingly.
See the chart on page 21.

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.

12

SAFETY

Operator Safety

Disabled Operators

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

WARNING

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

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. If your speed is 40 MPH (64 km/h), your snowmobile is traveling
about 60 feet (18 m) per second. If you look back for only two seconds,
your snowmobile will travel about 120 feet (36 m). If your speed is 60
MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in
two seconds.

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

13

SAFETY

RR

Operator Safety

Driver Awareness

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

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

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

14

SAFETY

Operator Safety

Avalanches

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

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

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

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

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

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

15

SAFETY

Operator Safety

Ice and Snow Build-up

WARNING

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

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

Driving Downhill

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

WARNING

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

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

16

SAFETY

Operator Safety

Driving on Slippery Surfaces

WARNING

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

Driving on ice or 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 in Hilly Terrain

WARNING

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

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

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

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

17

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 snowmobile into motion, but always operate within
safety limits and, on 2-up machines, with respect for a passenger.

Maneuverability

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

18

SAFETY

Operator Safety

Inadequate Snow Conditions

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

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

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

Operating in Deep Snow

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

the slide rail, track and/or engine.

WARNING

19

SAFETY

Operator Safety

Driving Responsibly

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

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

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

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

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

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

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

20

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

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

in

MPH

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

5 3631251913 7 1 -5-11-16

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

15 32 25 19 13 6 0 -7 -13

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

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

30 28 22 15 8 1 -5 -12

35 28 21 14 7 0 -7 -14

40 27 20 13 6 -1 -8 -15

45 26 19 12 5 -2 -9 -16

50 26 19 12 4 -3 -10 -17

55 25 18 11 4 -3 -11

60 25 17 10 3 -4 -11

Frostbite in >>

Actual Thermometer Reading (_F)

Equivalent Temperature (_F)

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

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

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

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

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

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

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

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

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

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

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

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

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

30 min. 10 min. 5 min.

WIND CHILL CHART (°C)

Wind

Speed

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

in

KPH

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

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

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

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

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

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

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

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

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

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

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

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

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

Frostbite in >>

Actual Thermometer Reading (_C)

Equivalent Temperature (_C)

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

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

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

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

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

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

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

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

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

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

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

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

30 min. 10 min. 5 min.

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

21

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

The clutch cover warning decal is under the hood on the clutch cover.

WARNING

Do not operate engine with hood open.

Do not attempt adjustment with engine running.

Do not operate engine with plenum/belt guard removed.

Never run engine with drive belt removed.

Never service clutches yourself. See your dealer.

Pressure Cap Warning

The pressure cap warning decal is found under the hood on the pressure
cap of applicable liquid cooled models.

WARNING

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

22

Safety Decals and Locations

“No Passenger”

Warning

Hot Surface
Warning

Tra ck
Warning

“No Passenger” Warning

Snowmobiles designed for only a
single rider have a warning decal
on the console below the steering
post.

WARNING

This vehicle is designed for
operator only.

“NO PASSENGER”

Track Warning

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

WARNING

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

Hot Surface Warning

The hot surface warning is on the
rear center of the tunnel.

WARNING

Hot Surface

Do Not Touch

Burns may result. Entire top of
tunnel may be hot. Install only
accessories specifically
approved for this model by
Polaris. Do not place clothing,
bags or cargo on tunnel. Do not
cover this label.

SAFETY

23

SAFETY

Reverse Warning

Operation Warning

Safety Decals and Locations

Reverse Warning

Polaris snowmobiles equipped with
electric reverse have a reverse warning
decal on the console.

WARNING

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

• Look behind before and while
backing up.

• Avoid sharp turns.

• Shift to or from reverse only when
stopped.

• Apply throttle slowly.

NOTE: For more information, see
Owner's Manual.

If electric reverse:

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

• Push button again to return to forward.

Operation Warning

The operation warning decal is located on the console of all Polaris
snowmobiles.

WARNING

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

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

(continued on next page)

24

SAFETY

Safety Decals and Locations

Operation Warning

(continued from previous page)

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

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

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

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

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

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

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

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

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

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

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

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

25

FEATURES

16

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

2. Hood

3. Headlight

4. Windshield

5. Mountain Bar (if equipped)

6. Handlebar

7. Seat

8. Taillights

9. Rear Bumper

10. Snow Flap

11. Track

12. Suspension

13. Tunnel

14. Side Panel

15. Ski

16. Nosepan

1

2

16

11

10

9

15

6

5

4

3

7

8

12

13

14

26

FEATURES

1. Fuel Filler Cap

2. Ignition Switch

3. MFD (Multi-Function Display)

4. Engine Stop Switch

5. Throttle Control

6. Recoil Starter Handle

7. Hood Hold-Down Straps

8. Brake Lever

9. Parking Brake

10. Handlebar Grip Warmer
Switch

11. Thumbwarmer Switch

12. Electronic Reverse Button

13. MFD Control

14. Headlight Dimmer Switch

1

2

8

3

4

5

7

6

14

9

10

11

12

13

2

3

4

5

7

6

10

14

13

12

9

8

27

FEATURES

Dimmer Switch Dimmer Switch (Dragon)

Adjuster

Headlight Dimmer Switch

Use the headlight dimmer switch to adjust the headlights between high
beam and low beam. Switch headlights to low beam when meeting
oncoming traffic.

Adjustable Headlights

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

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

Adjustable Steering

The adjustable steering system allows you to adjust the handlebar posi­tion to fit your style of riding. See page 47.

Accessory Cargo System

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

28

FEATURES

Detonation Elimination Technology (DET)

A detonation sensor monitors the engine and responds to detonation by
automatically reducing the engine timing and adding fuel. This results in
decreased engine RPM and performance.

Effect of DET

The DET system prevents damage to the engine from detonation while
developing the maximum power of the engine safely. If the system
senses detonation beyond a preset limit, it retards ignition timing and
adds fuel to reduce the detonation and prevent engine damage.

When the detonation returns to a permissible level, the system will
return spark and fuel to normal, allowing the engine to run at rated
power levels.

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.

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

disconnected.

29

FEATURES

1

2

3

5

6

7

8

4

Instrumentation

MFD Component Identification

Item

1 Analog Gauge (if

equipped)

2 Digital Gauge

3 Check Engine Indicator

4 Low Oil Indicator

5 High Temp Indicator

6 Brake Indicator

7 Reverse Indicator

8 High Beam Indicator

30

Instrumentation

1

2

3

4

5

6

Digital Display Identification

Item

1 RPM or Speed

Altitude (if equipped)
Service Interval

2 Electrical System

Voltage Level

3 MAX - Maximum MPH/

4 Air Temp (if equipped)

5Miles

6Hours

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

revolutions per

minute

Engine Temp
Degrees Celsius
Degrees Fahrenheit

Kilometers

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

FEATURES

31

FEATURES

MFD Control Switch (Dragon)

MFD Control Switch

SET

MODE

Instrumentation

MFD Settings

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

Standard vs. Metric

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

Speedometer/Tachometer

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

Option Digital Display Screen Backlight

1 RPM Blue

2 Speed Red

32

FEATURES

Instrumentation

MFD Digital Display Programs

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

Performance Program

Press and release the MODE button until the performance program
screen is active. The default display for this screen includes electrical
system voltage, fuel level (if equipped) and either speed or tachometer,
whichever is selected (see page 32).

Press and release the SET button to cycle through the following screens:
odometer, trip 1 odometer, trip 2 odometer, fuel trip odometer (if fuel is
low) and clock (if equipped). Use the following procedures to make
changes to these screens.

Odometer Setting

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

Trip Settings

Trip 1 and Trip 2 are odometers used to
check fuel mileage or to keep track of
distance traveled. Both odometers can be
reset to zero.

1. Enter the Performance Program.

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

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

4. Press and release the SET button to view another trip screen if
desired.

33

FEATURES

Instrumentation

MFD Digital Display Programs

Performance Program

Trip Settings

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

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

Engine Program

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

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

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

Engine Program

Air Temperature (accessory)

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

Altimeter (accessory)

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

TIP: When “ALt-FT” displays, the program is in the

standard mode. If only "ALt" displays, the
program is in the metric mode.

1. Enter the Engine Program.

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

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

4. When the digits begin to flash, release the SET button.

5. Press and release the SET button to advance the reading in 50-foot
(15 m) increments, or press and hold the button to advance quickly.
Adjust the altitude display to within 50 ft. (15 m) of the current
altitude.

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

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

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

35

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

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

Press and release the SET button to cycle through the following screens:
maximum vehicle speed, maximum engine RPM and service interval
reminder.

Maximum Speed/Maximum RPM

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

1. Enter the History Program.

2. Press and release the SET button until
one of the two screens is active. The
MPH and RPM values are both reset at
the same time. Reset the values before
each run to obtain accurate readings.

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

TIP: Due to electrical noise, the MFD may

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

36

FEATURES

Instrumentation

MFD Digital Display Programs

History Program

Service Interval Reminder

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

To reset the reminder at the existing interval:

1. Enter the History Program.

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

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

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

To reset the reminder at a new interval:

1. Enter the History Program.

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

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

4. Press the button again, up to five times, to advance the reminder in
20-hour increments. The maximum interval is 200 hours.

To disable the service interval reminder, press the SET button once after
reaching 200 hours on the display. The gauge will display "OFF".

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.

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

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

38

THE PERFECT FIT

1

2

3

5

4

IQ Front Suspension Adjustments

Independent Front Suspension (IFS)

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

Settings will vary from rider to rider, depending on rider weight, vehicle
speed, riding style, and trail conditions. We recommend starting with
factory settings and then customizing each adjustment individually to
suit rider preference. The snowmobile should be methodically tested,
one change at a time, under the same conditions (trail and snow condi­tions, vehicle speed, riding position, etc.) after each adjustment until the
best ride is achieved.

IFS Components

1. Ski

2. Front shock and spring

3. Rod ends

4. Upper control arms

5. Lower control arms

IFS Adjustment Options

• Shock spring preload

• Shock valving

• Optional springs

• Toe (ski alignment) (see
page 104)

• Camber (see your dealer)

39

THE PERFECT FIT

1

2

3

5

4

6

IQ Front Suspension Adjustments

WARNING

Always verify ski alignment before making adjustments to the IFS. See page
104 to check alignment. If the skis are misaligned, see your dealer, as the
camber adjustment may also be affected.

Air Shocks

Walker Evans air shocks can be adjusted for preload and valving. Please
see your Polaris dealer for these adjustments.

Standard Shocks

The tension at which the shock coil spring is set is called spring preload.
For the best ride, the suspension should be adjusted to use the full travel
of the shocks with occasional light bottoming. To determine if your
machine is using full travel, push the jounce bumper down on the shock
rod until it contacts the body and test ride the machine. The bumper will
move up on the rod in relation to the amount of travel that was used dur­ing the ride. If the travel is full, the bumper will be seated at the top of
the rod.

Shock Absorber Components

1. Retainer

2. Jounce Bumper

3. Shock Rod

4. Body

5. Threaded Spring Preload Adjuster Nut

6. Spring (Standard only)

40

THE PERFECT FIT

Stiffer Softer

Adjustment

Wrench

Full Firm

Full Soft

IQ Front Suspension Adjustments

Front Shock Springs

(Standard Only)

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.

Front Shock Spring Rate

(Assault Model)

The Assault IFS shocks are equipped
with an adjustable spring rate feature.
This adjustment will not affect the pre­load (ride height) of the vehicle. There
are eight lines scribed in the body of the
reservoir that represent the adjustment
range of the spring rate. To make
adjustments, turn the large red cap on
the reservoir with the aluminum
wrench supplied with your vehicle.

NOTICE: To avoid damage, use only the

As viewed from the bottom of the cap:

• Turn the cap clockwise for a stiffer

• Turn the cap counterclockwise for a

The shocks are delivered in the full soft
position (8th line). Each line represents
approximately 40 pounds of spring rate
at mid stroke on the shock. Make
adjustments in two line increments
maximum, as this will have a large
effect on the ride of the vehicle.

supplied wrench to adjust the
shock. Never use the service port
as it may crack and cause a loss
of pressure.

ride.

softer ride.

41

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

• Rider weight usually determines the position at which the spring pre­load should be set. However, this may vary with riding style. With a
little experimentation, each rider can find a preferred set-up. These
adjustments are easy to make, involve very little time or effort, and
greatly affect the ride.

• In deep snow, a new rail slide will offer improved performance over a
worn slide. It can also improve top speed.

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

rust build-up and ensure proper function of the suspension components.
Grease rear suspension pivots before adjusting the rear suspension. Refer
to the suspension lubrication information beginning on page 76.

42

THE PERFECT FIT

X

Y

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

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

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

TIP: The rear bumper may need to be

lifted upward slightly to fully extend
the 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 this rear
suspension is five inches (12.7 cm) (X-Y=5 in./12.7 cm).

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.

43

THE PERFECT FIT

Soft Medium

Firm

High

Low

Rear Suspension Adjustments

Torsion Spring Preload

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

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

Soft (long end of cam to front)

Medium (short end of cam up)

Firm (long end of cam up)

Limiter Strap Position

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

desired riding style.

High: Limiter strap in high position
increases ski pressure

Low: Limiter strap in low position
decreases ski pressure

44

THE PERFECT FIT

Stiffer Softer

Stiffer Softer

Rear Suspension Adjustments

Shock Compression Valving

Standard Rear Track Shock

The standard RMK rear track shock is an
Arvin MPV Select shock that allows for
adjustments to the compression valving.
Adjustments are made by turning the
adjustment screw located near the base of
the shock. In half-turn increments:

• Turn the screw clockwise for a stiffer

ride.

• Turn the screw counterclockwise for a

softer ride.

If bottoming continues after the screw has
been turned fully clockwise, the torsion
spring should be adjusted (see page 44).
Return the screw to its original starting
position after the torsion spring has been
adjusted.

Assault Rear Track Shock

Turn the adjustment knob on the shock
reservoir to make adjustments to the com­pression damping. When adjusting, we
recommend that you turn the adjuster
slightly, then test ride.

• Turn the knob clockwise for a stiffer

ride.

• Turn the knob counterclockwise for a

softer ride.

45

THE PERFECT FIT

Handlebar Adjustments

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 handlebar position.

Handlebar position and handlebar angle can be adjusted to rider prefer­ence. After making handlebar adjustments, check to make sure wires are
not pinched or kinked. Make sure the handlebars, brake lever and throt­tle lever operate smoothly and do not hit the gas tank, windshield or any
other part of the vehicle when the handlebars are turned fully to the left
or right.

When adjustments are complete, torque the front adjuster block bolts
first, then torque the rear bolts. Torque the bolts to 11-13 ft. lbs. (15-18
Nm).

46

Handlebar Adjustments

Loosen top bolts to adjust
handlebar angle

Loosen bottom bolts to
adjust handlebar position

Handlebar Position

1. Loosen the four bolts on the

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

2. Adjust the handlebar forward

or rearward to the desired
position.

3. Tighten the bolts.

Handlebar Angle

1. Loosen the four bolts on the

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

2. Adjust the handlebar forward

or rearward to the desired
angle.

3. Tighten the bolts.

THE PERFECT FIT

47

THE PERFECT FIT

Accessories

Polaris offers a wide range of accessories for your snowmobile to help
make each ride more enjoyable.

Use only Polaris parts and accessories on your Polaris snowmobile. Use
of unapproved parts and accessories may result in:

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others

This applies, but is not limited to the following areas: brakes, clutches,
fuel systems, and exhaust systems. Exhaust systems are critical safety
areas that must use approved Polaris parts. Please see your Polaris
dealer for service.

Tether Switch

The accessory tether switch is available for all models. Order part num­ber 2870668.

48

PRE-RIDE INSPECTIONS

Pre-Ride Checklist

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

Item See Page

Drive Belt Condition 95

Steering System 53

Recoil Rope 51

Parking Brake Lock/Brake Lever/Brake System 51, 52, 89

Throttle Lever 50

Throttle Safety Switch 50

Auxiliary Shut-Off Switch (Engine Stop Switch) 55, 65

Ignition Switch 55, 65

Taillight/Brakelight/Headlight 55

Coolant Level 84

Gearcase Oil Level N/A

Engine Oil Level 77

Suspension Mounting Bolts 54

Skags (Wear Bars) 105

Ski Saddle and Spindle Bolts 54

Hood Straps/Latches 50

Seat Latches (if equipped) N/A

Rear Wheel Idler Bolts 54, 101

Tether Switch/Strap 55

Track Alignment/Condition 53, 102

Rail Slide Condition 106

Chaincase Oil Level 77

Oil Level 62

49

PRE-RIDE INSPECTIONS

Before Starting the Engine

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

WARNING

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

Read and Understand Your Owner's Manual

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

n Throttle Lever

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

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

n Throttle Safety Switch

Test the throttle safety switch system before the snowmobile is operated.
See page 63 for procedure.

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.

50

PRE-RIDE INSPECTIONS

1/2" (1.3 cm)

Before Starting the Engine

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 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 92.

Brake Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 91.

Check for the presence of air in the fluid system. See page 92 for more
information, or see your dealer for service.

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.

WARNING

51

PRE-RIDE INSPECTIONS

1

2

3

4

1

2

3

4

Before Starting the Engine

n Parking Brake Lever Lock

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

1. Brake Lever

2. Parking Brake Lever Lock

3. Master Cylinder Reservoir/

Cover

4. Fluid Level Indicator

Lock Engagement

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

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

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

Lock Release

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

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

WARNING

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

52

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Steering System

Manually turn the skis completely to the right and to the left. If any dif­ficulty is encountered, remove any ice and snow build-up that may be
obstructing the steering linkage.

n Track Inspection

WARNING

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

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

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.

NOTICE: High speed use on hard-packed 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.

53

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Suspension Inspection

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

Item Check Page

Suspension mounting bolts Tightness --

Rear idler wheel bolts Tightness 101

Rear idler adjusting bolt locknuts Tightness --

Torque arm bolts Tightness --

Carrier and bogie wheel bolts Tightness --

Front torque arm limiter strap Condition --

Rail slide Condition 106

Track Tension 100

All rear suspension components Lubrication 75

Ski runner/skag Condition --

Ski spindle bolts Tightness --

Tie rod end nuts Tightness --

54

PRE-RIDE INSPECTIONS

Start the Engine and Check

Before starting the engine, always refer to all safety warnings pertaining
to snowmobile operation. Never engage the starter when the engine is
running. Never start the engine without checking all vehicle components
to be sure of proper operation. See Before Starting the Engine beginning
on page 50.

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 Te t h er Sw it ch

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 snowmobile.

55

OPERATION

Starting the Engine

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

1. Turn the key to the ON position. Pull the engine stop switch up to

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

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

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

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

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

TIP: It may require as many as eight to ten pulls to prime the fuel system and

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

the RUN position.

CAUTION

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

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

snap back into the housing. Damage may result.

start the engine if the fuel tank has been completely emptied.

56

OPERATION

Engine Break-In

No single action on your part is as important to long, trouble-free
machine life as proper break-in of a new or rebuilt engine. Premix the
first tank of 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.

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

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

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

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

57

OPERATION

Engine Break-In

Oil Injection System

Always fill the oil reservoir when refueling.

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

Oil Recommendations

This snowmobile is equipped with a variable exhaust system (VES).
Engine lubrication comes from oil added to the fuel and oil injection
systems. Polaris recommends the use of VES II 2 Cycle Oil for this
engine. See page 110 for the part numbers of Polaris products.

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

Slide Rail and Track Cooling

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

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

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

58

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.

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

temperatures.

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

the snowmobile to the ground.

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

to loosen snow and ice.

59

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

• Always turn off the engine before refueling.

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

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

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

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

WARNING

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

60

OPERATION

Fuel

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

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

Fuel System Deicers

If you use non-oxygenated fuel, Polaris recommends the regular use of
isopropyl-based fuel system deicer. Add one to two ounces per gallon
(8-16 ml per liter) of gasoline to prevent engine damage resulting from
fuel system icing and lean fuel mixtures. Never use deicers or additives
containing methanol. Polaris also recommends the use of Carbon Clean
Plus. See page 110 for the part numbers of Polaris products.

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

damage. Perform maintenance as recommended.
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.

61

OPERATION

Oil

n Low Oil Indicator Light

The low oil indicator light will alert the operator if the oil level is low.
Visually check for oil in the bottle. Add oil before further operation of
the snowmobile. See page 58 for oil recommendations.

NOTICE: Operating the snowmobile without adequate engine lubrication can

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.

Maintain the oil level at the bottom of the filler neck. Always check and
fill the oil tank when refueling. Never operate the engine if oil is not vis­ible in the tank.

TIP: The Polaris oil cap on the oil bottle is vented to allow proper oil flow. See

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

your Polaris dealer for recommended replacement parts.

62

OPERATION

Stop
Switch

n Engine Stop Switch

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

to allow restarting.

n Throttle Safety Switch

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

WARNING

Operating the snowmobile with a faulty throttle safety switch can result in
serious injury or death in the event of an accident. If the throttle safety switch
does not shut off the engine during a 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. Lock the parking brake.

3. Start the engine and allow it to idle.

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

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

63

OPERATION

n Throttle Lever

WARNING

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

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

1. Turn the ignition switch to OFF.

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

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

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

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

TIP: Excessive freeplay in the throttle cable may cause the safety switch to

activate, preventing the engine from starting. If this occurs, return the
snowmobile 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
snowmobile with the throttle safety switch disconnected. Return the
snowmobile to an authorized Polaris dealer for service as soon as possi­ble.

64

OPERATION

n Emergency Stopping

The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 63 for more information about the
engine stop switch.

SYSTEM WHAT IT DOES

Ignition Switch Interrupts ignition circuit All

Brake Slows jackshaft All

Engine Stop Switch Interrupts ignition circuit All

Choke (if equipped) Floods engine Half throttle or less

Throttle Safety Switch Interrupts ignition circuit All

Tether Switch (if equipped) Interrupts ignition circuit All

THROTTLE

CONDITION

65

OPERATION

Electronic Reverse (PERCt)

Electronic reverse will activate only if the engine RPM is below 4000.
The maximum engine RPM will be 6000 when in reverse.

WARNING

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

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

• Look behind the snowmobile before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

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

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

66

OPERATION

Reverse Button

Electronic Reverse (PERCt)

Engaging Reverse

1. Stop the snowmobile and leave the
engine idling.

2. Make sure the area behind your

snowmobile is clear.

3. Push the reverse button on the left-

hand control for one second, then
release. The engine will automatically
reduce RPM and start a reverse
rotation.

TIP: A reverse light on the instrument panel will

indicate that the transmission is in reverse.

4. Apply the throttle slowly to make sure

the transmission is in reverse.

TIP: If the engine stops running, the

snowmobile will be in forward gear when
it's restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

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

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

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

forward.

67

OPERATION

Daily Storage

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

Remove the key and cover the snowmobile.

To w i n g

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

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

WARNING

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

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

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

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

68

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

MAINTENANCE

Emission Control Information

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

Emission Control Label

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

Emission Control Maintenance Requirements

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

69

MAINTENANCE

Emission Control Information

Owner's Responsibilities

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

70

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 125.

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

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

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

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

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

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

71

MAINTENANCE

Periodic Maintenance Interval Table

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

Item See

Clutch Alignment Offset
(without belt)

Drive Belt Condition 95 II II

Clutches (disassemble) 94 CC C

Belt Tension -- IIII

Clutch Sheaves 94 II II

Engine Mounts -- IIII

Recoil Rope -- IIII

Engine Torque Stop 97 II II

Cylinder Head Bolts -- III

Cylinder Base Nuts -- II I I

Ignition Timing BTDC -- III

VES System -- CC C I

Coolant Level 84 IIRI

Coolant Hose -- IIII

Heat Exchangers 87 II I I I

Coolant Circulation -- III

Coolant Leaks -- II II

Spark Plug Condition 79 II IRI

Exhaust Pipe 83 II

Exhaust Retaining
Springs

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

Page

150 mi.

(240 km)

94 II I

ENGINE/COOLING

83 II II

CLUTCH

500 mi.

(800 km)

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

72

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Hose Routing -- II II

Hose Condition -- II II

Fluid Leaks -- II II

Brake Pads 89 IIII

Brake Disc -- II II

Parking Brake 52 II II

Brake System 51, 89 I

Brake Fluid 91 R

Idle RPM -- II I

Throttle Lever 50, 64 II I I I

Oil Pump Lever
(synchronize)

Throttle Cable 76 LL L

Vent Lines -- II II

Throttle Position Sensor -- II I

Fuel Lines 82 II I I I

Fuel Filter 82 RR

Oil Filter 82 RR

Oil Lines 82 III

Air Box/Plenum -- II I I I

Fuel Injectors -- II I

Engine Stop Switch 63 II I I I

Throttle Safety Switch 63 II I I I

Ignition Switch -- II I I I

Taillight 55 II I I I

Brakelight 55 II I I I

Headlight 55 II I I I

Page

150 mi.

(240 km)

FUEL MANAGEMENT

-- II I

ELECTRICAL

500 mi.

(800 km)

BRAKES

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

73

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Ski Toe Alignment -- II I

Suspension Mounting
Bolts

Steering Fasteners -- II I IC

Rear Suspension
Fasteners

Walker Evans Air
Shocks

Suspension Shock Oil -- II II

Cooling Fins/Shroud -- II II

Drive Shaft Bearings 76 LL L I

Jackshaft Bearings 107 LL L I

Skags (Wear Bars) 105 II I I I

Ski Saddle/Spindle
Bolts

Drive Chain Tension 88 II I I I

Hood Latches 50 II I I I

Rear Wheel Idler Bolts 101 II I I I

Idler Bolt Jam Nut 101 II I I I

Rear Suspension Pivot
Shafts

Camber Alignment -- II I

Handlebar Centering -- I

Tether Switch and Strap 55 II I I I

Track Alignment 102 II I I I

Track Tension 101 II I I I

Front Limiter Strap -- II I I I

Rail Slide Condition 106 I

Chaincase Oil 77 II IRI

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

Page

150 mi.

(240 km)

-- II I I I

-- II I I I

-- See your dealer for service

-- II I I I

75 LL L

500 mi.

(800 km)

CHASSIS

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

at 1500 mi. (2000 km)

Pre-

Season

74

MAINTENANCE

+

+

+

+

Lubrication

Front Suspension

The front suspension does not require lubrication.

Rear Suspension

Lubricate the suspension pivot shafts with Polaris Premium All Season
Grease at the intervals outlined in the Periodic Maintenance Table
beginning on page 72 and before seasonal storage. When operating in
heavy, wet snow conditions, lubricate every 500 miles (800 km).

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

75

MAINTENANCE

Fitting

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.

76

Lubrication

Maintain Level Here

Sight Glass

Fill
Plug

n Chaincase Oil

Check the chaincase oil level at the
intervals outlined in the maintenance
charts beginning on page 71. The sight
glass is located on the lower rear of the
chaincase. Maintain the oil level at or
slightly below the center of the sight
glass. 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 110
for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on a level sur­face.

2. View the oil level at the sight glass.

3. Remove the fill plug and add the

recommended oil as needed. Do not
overfill.

4. Reinstall the fill plug, making sure it

is seated properly.

MAINTENANCE

77

MAINTENANCE

Drain Plug

Lubrication

Chaincase Oil

Oil Change

1. Position the vehicle on a level surface.

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

3. Clean off all metal shavings from the
plug.

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

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

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

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

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

78

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.

CAUTION

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

Normal Spark Plug

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

The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect carburetor/throttle
body adjustments.

Wet Fouled Spark Plug

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

79

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).

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

• Use recommended spark plugs with the proper gap.

• Use only resistor-type spark plugs.

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

• Always carry spare spark plugs.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the

3. Reverse the procedure for spark plug installation.

4. Torque to specification.

5. Reinstall the spark plug cap.

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

spark plug counterclockwise to remove it.

80

Intake Filters

Intake Foam Filters/Pre-filter

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.

NOTICE: Operating the snowmobile

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

MAINTENANCE

81

MAINTENANCE

Fuel Injectors

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

Fuel Pump

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

Fuel Filter

See your Polaris dealer for replacement of the fuel filter at the intervals
outlined in the Periodic Maintenance Table beginning on page 72.

Fuel Lines

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

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

Oil Lines

Inspect oil line condition at the intervals outlined in the Periodic Main­tenance Table beginning on page 72.

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

Oil Filter

Have your dealer change the oil filter
and bleed the system at the intervals
outlined in the Periodic Maintenance
Table beginning on page 72.

TIP: The direction of the arrows indicates

the direction of flow through the
filter.

82

MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at the intervals outlined in
the Periodic Maintenance Table beginning on page 71.

CAUTION

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

Always allow the engine and exhaust system to cool completely before
inspecting.

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

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

grommets.

3. Check for loose clamps on the pipe covers.

83

MAINTENANCE

Cooling System

Coolant

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

Use 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 110 for the part numbers of Polaris prod­ucts.

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

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

n Coolant Level

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

• Coolant bottle or overflow tank

• Filler neck

• Pressure cap

• Connecting hoses
Always maintain the coolant level between the minimum and maximum

marks on the coolant bottle (when engine is cold) to prevent overheating
and serious engine damage.

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

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

84

MAINTENANCE

Cooling System

Coolant High Temperature Indicator Light

The high temperature indicator light will illuminate when engine cool­ant temperature becomes too hot for safe continued operation of the
engine. If you must drive your snowmobile 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.

TIP: Engine performance will be reduced if you continue operating when the

high temperature light is on.

Flushing the Cooling System

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

85

MAINTENANCE

Cooling System

Bleeding the Cooling System

CAUTION

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

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

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

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

86

MAINTENANCE

Cooling System

Bleeding the Cooling System

Bleed the cooling system at the intervals outlined in the Periodic Main­tenance Table beginning on page 72. Perform the bleeding procedure
when the engine is cold.

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.

87

MAINTENANCE

Adjuster

Bolt

Jam

Nut

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.

3. Finger tighten the adjuster

bolt 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.

88

MAINTENANCE

Brakes

n Hydraulic Brake Inspection

Inspect the brake lever travel before each use of the snowmobile. See
page 51.

Brake pads must be replaced when the brake pad material becomes thin­ner than the backing plate, approximately 1/16" (1.5mm). 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" (1.5mm).

89

MAINTENANCE

Brake Disc

Bleed Screw

Brake Pad

Material

Brake Line

Brake

Caliper

Brakes

Brake Components

•Brake Disc

• Bleed Screw

•Brake Line

• Brake Caliper

• Brake Pad Material -

Replace when thickness is
less than 1/16" (1.5mm).

Excessive Lever Travel

Hydraulic brakes are self­adjusting, but if excessive
brake pad clearance develops
(see page 89) bring the snow­mobile to an authorized
Polaris dealer for inspection
and adjustment.

90

MAINTENANCE

Sight
Glass

Brakes

n 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.

NOTICE: 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 110 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.

91

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

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

WARNING

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

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

1. Remove brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX

marks or 1/4"-5/16" (.6-.8 cm) below the lip of the reservoir
opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder

valve 3/4 of a turn to release air.

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

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a

solid stream free of air bubbles.

WARNING

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

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

See page 91.

8. Reinstall the gasket and cover.

92

MAINTENANCE

Spring

Harness

Bulb

Screws

Lights

Removing Halogen Bulbs

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

1. Remove the plenum cov­ering from the headlight
assembly.

2. Lift the rubber boot to

expose the bulb.

3. Push down on the spring

to release it from the
housing.

4. With the wire harness

attached to the bulb,
withdraw the bulb from the housing.

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

from the harness.

Installing Halogen Bulbs

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

2. Insert the bulb into the housing.

3. Connect the spring to the housing.

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

wire harness.

5. Reinstall the plenum covering on the headlight assembly.

6. Adjust headlight aim. See page 28.

Replacing Taillight Bulbs

1. Remove the screws securing
the taillight lens.

2. Remove the bulb and install a

new bulb.

3. Reinstall the lens.

93

MAINTENANCE

Clutch System

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

WARNING

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

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

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

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

Clutch Alignment Offset

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

Clutch Center Distance

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

94

MAINTENANCE

Clutch System

n Drive Belt Condition

Belt width and length must match the center distance of the clutches and
sheave width of the drive clutch. For this reason, Polaris recommends
that only O.E.M. belts be used. Other belts may match the dimensions,
but can drastically change the shift pattern, resulting in poor perfor­mance. See Drive Belt Troubleshooting on page 115.

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.

TIP: A worn belt will continue to function, but will not deliver maximum

performance. Always carry a spare belt in case of an emergency.

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 Installation

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

TIP: 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.

95

MAINTENANCE

11:0 0

2:00

Access Hole

Clutch System

Drive Belt Removal

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

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

TIP: For easier accessibility, make sure the clutch tool access hole is visible

2. Turn the ignition key off.

3. Lock the parking brake.

4. Open the hood.

5. Remove the left side panel.

6. Locate the L-wrench in the

7. Turn the wrench clockwise

snowmobile must be stopped after forward motion to prevent damage
to components during belt removal.

between the 11:00 and 2:00 positions of the clutch sheave.

Wait for the engine to come
to a complete stop.

tool kit. Install the wrench
into the open threaded access
hole in the outer sheave of
the clutch.

until the sheaves open far
enough to remove the belt.

96

MAINTENANCE

Straight

Edge

Measure

A

.010"-.030"
(.25-.75 mm)

Clutch System

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
and apply downward pressure
while measuring at point A. This
measurement should be 1 1/4"
(3.2 cm).

Drive Belt Adjustment

1. Install the L-wrench into the open threaded hole in the outer sheave
of the clutch (see page 96). Turn the wrench clockwise slightly to
remove pressure from the sheaves.

2. Loosen the 7/16" jam nut.

3. Using a 1/8" Allen wrench, turn the set screw inward (clockwise) to

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

4. Tighten the jam nut. Store the L-wrench in the tool kit.

To r q u e S t o p

Periodically check torque stop clear­ance. With clutches in proper align­ment, measure rear torque stop
clearance from the engine case. Rear
torque stop clearance should be .010"­.030" (.25-.75mm). Adjust if neces­sary. Secure the nut.

97