Polaris 600 Switchback Adventure, 600 Switchback Pro-R, 800 Switchback Pro-R Adventure, 800 Switchback Pro-R, 800 Switchback Owner's Manual

PMS 419

Modifications to this snowmobile are not recommended

and may result in voided warranty coverage.

Please read the warranty section of this manual carefully.

IMPORTANT NOTICE TO OWNER

Snowmobile Owner's Manual

for Maintenance and Safety

600 Switchback®

600 Switchback® Pro-R

600 Switchback Adventure™

800 Switchback®

800 Switchback® Pro-R

800 Switchback® Pro-R Adventure

WARNING

Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

1

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polaris.com for the latest news, new product introductions,
upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and

recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• VICTORY® motorcycles

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

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

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

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

2

POLARIS, PERC, PRO-RIDE and SWITCHBACK are registered trademarks of
POLARIS Industries Inc.

SWITCHBACK ADVENTURE is a trademark of POLARIS Industries Inc.
Copyright 2013 POLARIS Sales Inc. All information contained within this publication

is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies could 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 inacc uracies. Any reprin ting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

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

Printed in U.S.A.
2014 600 SWITCHBACK/800 SWITCHBACK Owner's Manual
P/N 9924269

3

TABLE OF CONTENTS

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

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

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

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

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 46

This section includes a Suspension Quick Set-Up Guide and explains
how to make additional suspension adjustments for the perfect riding
experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 60

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

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

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

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

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 122

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 134

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

4

5

INTRODUCTION

Important Notes for Owners and Drivers

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

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

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

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

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

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

6

INTRODUCTION

Preservation of the Environment

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

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

Noise Level

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

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

Air Pollution

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

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

7

INTRODUCTION

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

Tunnel VIN (right side of tunnel): ____________________________________________

Engine Serial Number (on recoil housing): _____________________________________

Key Number: ____________________________________________________________

Tunnel VIN

8

SAFETY

Operator Safety

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

The safety alert symbol indicates a potential personal injury ha zard.

DANGER

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

WARNING

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

CAUTION

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

NOTICE

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

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

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

9

SAFETY

Operator Safety

Follow the recommended maintenance program beginning on page 81
of this manual to ensure that all critical components on the snowmobile
are thoroughly inspected by your dealer at specific mileage intervals.

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

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

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

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

WARNING

10

SAFETY

Operator Safety

Stay Clear of Track

Your snowmobile is propelled by a revolving track that must be partially
exposed for proper operation. Do not stand on the plastic flap.

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, open the side panels or hood, make the adjustment, secure shields
and guards, secure the side panels and hood, and then restart the engine
to check its operation.

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

Riding Position

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

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

NO

STEP

11

SAFETY

Operator Safety

Riding Apparel

Helmet

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

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

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

Eye Protection

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

Clothing

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

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

E

4

051039

0006.31

12

SAFETY

Operator Safety

Disabled Operators

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

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

13

SAFETY

Operator Safety

Rider Capacity

This snowmobile is designed for a single rider only. Never carry a pas­senger on this snowmobile.

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.

14

SAFETY

Operator Safety

Driver Awareness

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

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

Variances in snow depth and/or water currents may result in uneven ice
thickness. You may drown if you break through the ice. Never travel on
frozen bodies of water unless you have first verified that the ice is suffi­ciently thick to support the weight and moving force of the snowmobile,
you and your cargo, together with any other vehicles in your party.
Always check with local authorities and residents to confirm ice condi­tions and thickness over your entire route. Snowmobile operators
assume all risk associated with ice conditions on frozen bodies of water.

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

RR

15

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.

16

SAFETY

Operator Safety

Ice and Snow Build-up

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

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

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

Driving on Slippery Surfaces

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

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

Inadequate Snow Conditions

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

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

the slide rail, track and/or engine.

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

Operating in Deep Snow

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

17

SAFETY

Operator Safety

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.

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 roll-over.

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

If you're unable to continue up a hill, turn the 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.

18

SAFETY

Operator Safety

Drive Belt

Do not operate the engine with the drive belt removed.

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

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

damage to the engine.

Intake Silencer

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

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

removed.

Clutches

Do not attempt to service the clutches.

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

Cold Weather Drive-Away

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

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.

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 snowmobile and with
what it will and won't do under various conditions. Even seasoned driv­ers should spend some time getting the feel for a snowmobile 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.

WINDCHILL CHART (°F)

WINDCHILL CHART (°C)

Wind

Speed

in

MPH

Actual Thermometer Reading (°F)

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

Equivalent Temperature (°F)

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

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

5 3631251913 7 1 -5-11-16

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

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

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

15 32 25 19 13 6 0 -7 -13

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

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

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

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

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

30 28 22 15 8 1 -5 -12

-19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87
35 28 21 14 7 0 -7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89
40 27 20 13 6 -1 -8 -15

-22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91
45 26 19 12 5 -2 -9 -16

-23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93
50 26 19 12 4 -3 -10 -17

-24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95
55 25 18 11 4 -3 -11

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

60 25 17 10 3 -4 -11

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

Frostbite in >>

30 min. 10 min. 5 min.

Wind

Speed

in

Km/h

Actual Thermometer Reading (°C)

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

Equivalent Temperature (°C)

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

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

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

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

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

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

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

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

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

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

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

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

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

-30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70
56 -2 -6 -10 -14 -18 -22 -26

-31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72
64 -2 -6 -10 -15 -19 -23 -27

-31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73
72 -2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74
80 -3 -7 -11 -15 -20 -24 -28

-33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75
88 -3 -7 -12 -16 -20 -24

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

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

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

Frostbite in >>

30 min. 10 min. 5 min.

21

SAFETY

Safety Labels and Locations

W arning labels have been placed on t he snowmobile for your protection.
Read and follow the instructions of the labels and other warnings on the
snowmobile carefully. If any of the labels depicted in this manual differ
from the labels on your snowmobile, always read and follow the instruc­tions of the labels on the snowmobile.

If any label becomes illegible or comes off, contact your POLARIS
dealer to purchase a replacement. Replacement safety labels are pro­vided by POLARIS at no charge. The part number is printed on the
label.

Clutch Warning

This warning label is found on the oil bottle:

WARNING
Do not operate engine with hood or side panels open.
Do not attempt adjustment with engine running.
Do not operate engine with the clutch guard removed.
Never run engine with drive belt removed.
Never service clutches yourself. See your dealer.

Pressure Cap Warning

This warning label is found 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

Safety Labels and Locations

Track Warning

WARNING
Stay clear of track. Do not sit

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

No Passenger Warning/Fuel Recommendation Label

WARNING
This vehicle is designed for operator only. NO PASSENGER.

Reverse Warning

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 befo re 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.

Track

Warning

Reverse Warning

No Passenger Warning/Fuel

Recommendation Label

23

SAFETY

Safety Labels and Locations

Operation Warning

WARNING

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Operation

Warning

24

FEATURES

8

13

5

6

7

12

11

2

1

3

4

10

9

1. Nosepan

2. Skis

3. Front Bumper

4. Hood

5. Headlight

6. Windshield (accessory)

7. Handlebar

8. Operator Seat

9. Taillight

10. Rear Bumper

11. Sno w Flap

12. Suspension

13. Track

14. Side Panel

15. Side Panel Fast eners

16. Tool Kit/Storage Bag

15

14

16

25

FEATURES

1. Brake Lever

2. MFD Gauge

3. Ignition Switch

4. Engine Stop Switch

5. Throttle Control

6. Recoil Starter Handle

7. Parking Brake Lock

8. Handlebar Grip Warmer Switch

9. Thumbwarmer Switch

10. Electronic Reverse Button

11. Mode/Set Switch

12. Headlight Dimmer Switch

3

4

5

6

2

1

11

10

12

78 9

26

FEATURES

Adjustable Headlights

Move the headlight adjuster to the
left to adjust the headlight beam
upward. Move the adjuster to the
right to adjust the beam
downward.

Up

Down

27

FEATURES

Fuel Type Selection

Whenever using ethanol, MTBE or other forms of oxygenated gaso­lines, the fuel type designation setting must be changed to “Eth” in the
gauge. When using the recommended 91 non-ethanol gasoline, always
select the “91-non” setting.

Whenever in doubt of your fuel
purchase, use the “Eth” setting as
a safeguard.

Use the following procedure to
change the fuel type designation in
the gauge. Refer to the fuel type
selection label located inside the
left side panel.

1. Start the engine.

2. Lock the parking brake.

3. Press and release the
SELECT button or SET
switch until “FUEL” is dis­played in the lower section of
the gauge.

4. Press and hold the SELECT button or SET switch until the desired
fuel type is displayed in the center of the screen.

28

FEATURES

Detonation Elimination Technology (DET)

The DET system prevents damage to the engine from detonation by
going into an engine protection mode whenever the DET system is
active.

When excessive detonation is detected,
the check engine light will illuminate
and you may notice decreased engine
performance and RPM when the DET
system is activated. In most cases this
is temporary and the operator does not
need to take any action. The engine
will return to its normal performance
automatically.

If severe detonation occurs, the check engine light will begin to flash
steadily and the gauge indicator will read “dET” (see illustration). The
engine will enter a limp home mode and RPM will be limited to 6500
RPM. The engine will remain in this mode until it is shut down and
restarted.

Check Engine Light Indicates

Solid or Flickering Excessive detonation detected

Steady Flashing Severe detonation detected, RPM will be limited

29

FEATURES

Detonation Elimination Technology (DET)

The most likely causes of severe detonation are outlined in the trouble­shooting table below.

DET Troubleshooting

Security System (Ignition Lock System)

Your snowmobile has an optional security function that can be activated
by an authorized POLARIS dealer. If you have this feature activated,
you can lock the ignition to prevent unauthorized use when leaving the
snowmobile unattended. A locked system will limit engine speed to
3000 RPM, which prevents clutch engagement, and the snowmobile
will not move when throttle is applied.

If you wish to use this system, see page 37 of the Instrument Cluster
section for security system activation and operating instructions.

Cause of DET Activation Solution

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

type setting

Verify correct fuel type setting on

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

Ethanol fuel

Do not add deicers or additives that

contain any form of alcohol while

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

30

FEATURES

Instrument Cluster

The instrument cluster contains
indicator lights and the rider
information center . The information
center can be controlled by either
the MODE and SELECT buttons on
the instrument cluster or by the
MODE/SET switch on the left
handlebar.

NOTICE: Certain products will damage

the lens and other plastic sur­faces. Do not use alcohol to
clean the instrument cluster.
Immediately clean off any
gasoline that splashes on the
instrument cluster.

Rider Information

Center

Check Engine

Indicator

High Beam

Indicator

Low Oil

Indicator

Over-

Temperature

Indicator

Park Brake

Indicator

Reverse

Indicator

MODE

Button

SELECT

Button

Mode/Set

Switch

S

E

T

M

O

D

E

31

FEATURES

Instrument Cluster

Indicators

Check Engine Indicator

This indicator appears if an EFI-related fault occurs. Do not operate the
snowmobile if this warning appears. Serious engine damage could
result. See your dealer. See page 44 for diagnostic code definitions.

Over-Temperature Indicator

This indicator illuminates to alert the operator that the engine is over­heating. The operator should take action to cool the engine. See page 92.
If the indicator flashes, continued operation could result in serious
engine damage. Stop the engine immediately.

Low Oil Indicator

The low oil indicator light may flicker at times due to oil movement in
the bottle, but when the light comes on and remains on, add the recom­mended oil before further operation. See page 73.

High Beam Indicator

The high beam indicator illuminates when the lights are set to high
beam.

Parking Brake Indicator

This indicator illuminates when the parking brake is engaged. It will
also illuminate when the service brake is in use. See page 64.

Reverse Indicator

This indicator flashes when the snowmobile is in reverse. See page 78.

32

FEATURES

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. The
center displays vehicle speed, engine speed, odometer, resettable trip
meters (2), total engine hours of operation, fuel level, engine tempera­ture and diagnostic display mode.

Setting changes must be made with the engine running or with the vehi­cle powered by an external DC power supply connector.

The information center is set to display standard units of measurement
for distance and temperature. To change to metric units, see page 36.

2

3

6

4

5

1

33

FEATURES

Instrument Cluster

Rider Information Center

1. Information Display Area - This area displays either engine speed

or vehicle speed (whichever is not displayed in the speed display),
engine temperature and maximum vehicle speed. To change the dis­play, see page 34.

2. Speed Display - The speed display area displays either vehicle

speed or engine speed. To change the display, see page 34.

3. Fuel Gauge - The segments of the fuel gauge show the level of fuel

in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments including the fuel icon will flash. Refuel
immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the

fuel sensor circuit. See your dealer.

4. Odometer/Engine Hour Display - This area displays the odometer ,

Trip A, T rip B and engine hours. To change the display , see page 35.

5. Battery Power - This indicator illuminates when battery power is

low.

6. Playback Icon - The playback function allows the rider to record

and play back engine speed, vehicle speed and throttle position sen­sor information for up to three minutes. The playback icon flashes
while recording. See page 35.

34

FEATURES

Instrument Cluster

Rider Information Center

Speed Display Area

The speed display area displays either vehicle speed or engine speed.
Vehicle speed is displayed in either miles per hour (MPH) or kilometers
per hour (km/h). Engine speed is displayed in revolutions per minute
(RPM).

1. To change which item displays, first make sure the information dis­play area is set to display either engine speed or vehicle speed.

2. Press and hold the MODE button (on the instrument cluster) or the
MODE switch (on the left handlebar) for three seconds.

Information Display Area

This area displays either engine speed or vehicle speed (whichever is
not displayed in the speed display), engine temperature and maximum
vehicle speed. To change the display, press and release the MODE but-
ton or the MODE switch until the desired item is displayed.

35

FEATURES

Instrument Cluster

Rider Information Center

Odometer/Engine Hour Display Area

This area displays the odometer, Trip A meter, Trip B meter and engine
hours meter.

The odometer displays the total distance traveled by the vehicle since
manufacture. Each trip meter records the distance traveled by the vehi­cle on a trip if the meter is reset before each trip. The engine hour meter
displays the total hours the engine has been in operation since manufac­ture.

To change the display, press and release the SELECT button or the SET
switch until the desired item is displayed.

To reset a trip meter, press and hold the SELECT button or the SET
switch until the meter resets to zero.

Playback Function

The playback function allows the rider to record and play back engine
speed, vehicle speed and throttle position sensor information for up to
three minutes.

1. To begin recording, simultaneously press and hold the MODE and
SELECT buttons on the instrument cluster for three seconds. The
playback indicator will flash while the instrument cluster is record­ing.

2. To play back the recorded data, stop the vehicle and wait for engine
speed to drop below clutch engagement.

3. Simultaneously press and release the MODE and SELECT buttons
on the instrument cluster.

4. Applying the throttle will clear the display and return the instrument
cluster to normal operation.

36

FEATURES

Instrument Cluster

Rider Information Center

Standard/Metric Display

The odometer and temperature displays can be viewed in either standard
or metric units of measurement. Both displays change if units are
changed. The new settings will remain until changed by the operator.

Change Method 1

1. Press and release the MODE button or MODE switch until engine
temperature displays.

2. Press and hold the MODE button or MODE switch until the units

change.

Change Method 2

1. Press and release the SELECT button or SET switch until the
odometer displays.

2. Press and hold the SELECT button or SET switch until the units

change.

37

FEATURES

Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

This system is an optional feature and will not function until it has been
activated by your authorized POLARIS dealer. If you have this feature
activated, you can lock the ignition to prevent unauthorized use when
leaving the snowmobile unattended. A locked system will limit engine
speed to 3000 RPM, which prevents clutch engagement, and the snow­mobile will not move when throttle is applied.

If you wish to use this feature, you must complete all four tasks on the
following pages to have your system activated and to change the secu­rity code to one of your own choosing.

38

FEATURES

Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

First Time Use of Your Security System

Perform all tasks in the order shown if you wish to

activate and use the optional security system.

TASK 1: Activate the security system

See your authorized POLARIS dealer to have the optional security system
feature activated in the electronic contro l un it (ECU).

TASK 2: Lock the System the First Time

1. Start the engine and lock the parking brake.

2. Press and hold the MODE and SEL buttons for 3
seconds, then release. SECURE OFF should be
displayed. If not, repeat this step.

3. Wait until ENTER CODE displays, then press
and release SEL to advance the digit. When “0”
is displayed, press and release MODE to accept
the digit. TIP: If the ENTER CODE screen exits
due to inactivity, repeat step 2.

4. Press and release SEL to advance the second
digit. When “0” is displayed, press and release
MODE to accept the digit.

5. Press and release SEL to advance the third digit.
When “0” is displayed, press and release MODE
to accept the digit.

6. After accepting the third digit, view the display
screen. SECURE ON displays if the system locks.

NOTE: The system is now locked.

7. You must now unlock the system. Proceed imme­diately to TASK 3.

39

FEATURES

Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

First Time Use of Your Security System

TASK 3: Unlock the System

1. When the engine is running, the display will

alternate between SECURE ON and
ENTER CODE. Wait until ENTER CODE
displays, then press and release SEL to
advance the digit. When “0” is displayed,
press and release MODE to accept the
digit.

2. Press and release SEL to advance the second

digit. When “0” is displayed, press and release
MODE to accept the digit.

3. Press and release SEL to advance the third digit.

When “0” is displayed, press and release MODE
to accept the digit.

4. After accepting the third digit, view the display

screen. SECURE OFF displays if the system
unlocks.

NOTE: The system is now unlocked.

5. You must now enter a new security code. Proceed immediately to TASK 4.

TASK 4: Enter Your New Security Code

1. Immediately after locking and unlocking the system, and while SECURE

OFF is displayed, press and release the MODE button to bring up the
ENTER CODE screen.

2. When ENTER CODE displays, use the SEL and MODE buttons to select

and accept each digit of a new personal security code.

3. After accepting the third digit, view the display

screen. The new code and CODE SET will dis­play if the system accepted your new code. You
will not see this display again.

NOTE: Your new code is now set. The system is

NOT locked.

4. Record your new security code in a safe place for future reference.

Record your new personal security code here: __________________

TIP:If you lose your personal security code, see your dealer to have the code

reset to “000”. Then perform TASK 2 through TASK 4 to change the code
to one of your own choosing.

888

40

FEATURES

Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

Locking the System With Your Personal Security Code

1. Start the engine and lock the parking brake.

2. Press and hold the MODE and SEL buttons
for 3 seconds, then release. SECURE OFF
should be displayed. If not, repeat this step.

3. Wait until ENTER CODE displays, then
press and release SEL to advance the digit.
When the first digit of your security code is
displayed, press and release MODE to
accept the digit.

TIP:If the ENTER CODE screen exits due to inactivity ,

repeat step 2.

4. Continue to use SEL and MODE to select
and accept the remaining two digits of the
code.

5. After accepting the third digit, view the dis­play screen. SECURE ON displays if the
system locks. Engine speed is now limited
and the snowmobile cannot be driven.

TIP:When the engine is running, the display will alter-

nate between SECURE ON and ENTER CODE.

6. If BAD CODE displays, the screen will then
return to the ENTER CODE screen. Repeat
steps 3-5 to re-enter the security code.

41

FEATURES

Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

Unlocking the System With Your Personal Security Code

1. When the engine is running, the display
will alternate between SECURE ON and
ENTER CODE. Wait until ENTER
CODE displays, then press and release
SEL to advance the digit. When the first
digit of your security code is displayed,
press and release MODE to accept the digit.

TIP:When the system is locked and engine temperature is above 120° F (49°

C), the correct password must be entered within 60 seconds or the engine
will shut down.

2. Continue to use SEL and MODE to select
and accept the remaining two digits of the
code.

3. After accepting the third digit, view the
display screen. SECURE OFF displays if
the system unlocks.

4. Re-enter your code if BAD CODE
displays.

NOTE: The system is now unlocked.

42

FEATURES

Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

Changing to a New Security Code

Any time you wish to change your current security code to a new code,
perform TASK 2 through TASK 4 of the First Time Use of Your Secu­rity System procedure beginning on page 38. Instead of using the fac­tory default code “000” in TASK 2 and TASK 3, use your current
security code.

Security System Access Quick Reference

Now that you have become familiar with the procedure for locking and
unlocking the system, use the chart below as a quick reference.

Security System Access Quick Reference Chart

Action Result

St art engine + Lock
parking brake + Press
and hold both MODE +
SELECT (SEL)

Displays ENTER CODE (to lock the system)

Press SELECT (SEL) Advances a digit on the ENTER CODE screen
Press MODE Accepts a digit and displays the next digit position (if

any remain) on the ENTER CODE screen
or
Opens ENTER CODE screen if MODE is pressed

immediately after locking and unlocking the system
(to change your security code)

43

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Display Mode

The diagnostic display mode is for informational purposes only. Please
see your POLARIS dealer for all major repairs.

The diagnostic mode is accessible only when the check engine warning
indicator is illuminated and a diagnostic code is active.

Do not stop the engine if you want to view the active code (failure
code). Active codes cannot be retrieved if power is interrupted to the
instrument cluster. The codes will become inactive codes if power is
interrupted. Inactive codes are stored in the history of the unit. Please
see your POLARIS dealer to retrieve inactive codes.

Use the following procedure to view active codes.

1. Do not stop the engine.

2. With the brake engaged, press and release the SELECT button or

SET switch to toggle to the diagnostic display mode. When a code
is active, the diagnostic display mode will appear immediately fol­lowing the engine hour display.

TIP:When the diagnostic mode is displayed, the check engine warning indicator

will begin to flash.

3. A set of two numbers will appear in the display.

• The 2-6 digit suspect parameter number (SPN) in the information display

area indicates which component is generating the fault code.

• The 1-2 digit failure mode indicator (FMI) number in the odometer area

indicates the fault mode, such as open or short circuit.

4. More than one fault may be active. Press and hold the MODE but­ton or MODE switch for two seconds to toggle to the next active
code. Repeat until all codes are retrieved.

5. See page 44 for code definitions and failure descriptions.

44

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions

Open Load:

There is a break in the wires that lead to the item listed in

the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground:

The wire is shorted to ground between the electronic

control unit and the item listed in the chart.

Shorted Load:

The wires leading to the item listed in the chart are

shorted together, or the item has shorted internally.

Short-to-Battery:

The wire leading from the item listed in the chart to

the electronic control unit is shorted to a wire at battery voltage.

Diagnostic Codes

Component Condition SPN FMI

Throttle Position Sensor

Voltage Too High 51 3
Voltage Too Low 4

Abnormal Rate of Change 10
Vehicle Speed Sensor Data Erratic, Intermittent or Missing 84 2
Intake Air Temperature Sensor Voltage Too High 105 3

Voltage Too Low 4
Barometric Pressure Sensor

Voltage Too High 108 3

Voltage Too Low 4
Engine Temperature Sensor

Voltage Too High 110 3

Voltage Too Low 4

Temperature Too High 16

Engine Overheat Shutdown 0

Temperature Above Normal Range 15
Alternator Power Supply

Potential (DC Chassis Voltage)

Voltage Too High 167 3

Voltage Too Low 4
Exhaust Temperature Sensor

Voltage Too High 173 3

Voltage Too Low 4

45

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions

Diagnostic Codes

Component Condition SPN FMI

ECU Memory Checksum/CRC Error 628 13
Injector 1 (MAG) (Port Injector) Driver Circuit Open/Grounded 651 5

Driver Circuit Short to B+ 3

Injector 2 (PTO) (Port Injector) Driver Circuit Open/Grounded 652 5

Driver Circuit Short to B+ 3
Knock Sensor 1 Voltage Too Low 731 4
Ignition Coil Primary Driver 1

(MAG)

Driver Circuit Open/Grounded 1268 5
Fuel Pump Driver Circuit Driver Circuit Open/Grounded 1347 5

Knock Level Cylinder 1 (MAG) Maximum Detonation Correction

Limit Reached

1352 0

Knock Above Critical Level 16
Knock Level Cylinder 2 (PTO) Maximum Detonation Correction

Limit Reached

1353 0

Knock Above Critical Level 16
Sensor Supply Voltage 1 (TPS/

TMAP Sensor Power)

Voltage Too Low 3509 4
Sensor Supply Voltage 2

(Ground Speed Sensor)

Voltage Too Low 3510 4
ECU Output Supply Voltage 2

(Injection Supply PWR)

Voltage Too High 3598 3

Voltage Too Low 4
Throttle Release Signal Voltage Too High 520194 3

Voltage Too Low 4

Throttle Stuck 7
Chassis Relay Driver Circuit Open/Grounded 520208 5

Driver Circuit Short to B+ 3
Exhaust Valve Solenoid Driver Circuit Grounded 520215 5

Driver Circuit Short to B+ 3
Injector 1 (MAG) (Case Injector) Driver Circuit Open/Grounded 520216 5

Driver Circuit Short to B+ 3

Driver Circuit Grounded 4
Injector 2 (PTO) (Case Injector) Driver Circuit Open/Grounded 520217 5

Driver Circuit Short to B+ 3

Driver Circuit Grounded 4
Fuel Type Selected Voltage Too High 524007 3

Voltage Too Low 4

Signal Out Of Range 2

46

THE PERFECT FIT

Suspension Quick Set-Up Guide

The suspension on this snowmobile is incredibly easy to adjust to rider
weight and riding style. Just remember three simple steps:

1. Set up rear shock spring preload for rider weight.

2. Adjust the rear spring to tune vehicle balance (ski pressure and
weight transfer).

3. Adjust shock clickers to tune ride quality (stiffer or softer ride).

The following Quick Set-Up Guide walks you through what you need to
know to get started, and additional detail is available on the pages
immediately following the guide. See pages 48-49 for factory and initial
suspension charts for the standard spring as well as for accessory
springs that are available for heavier or lighter riders.

Step 1: Set up rear shock spring preload for rider weight.

Before riding for the first time, use the gauge supplied with your snow­mobile to adjust rear spring preload to the appropriate setting for actual
rider weight.

Position the narrow end of
the gauge flush with the
spring retainer. Turn the
spring until the rider’s
weight setting aligns with
the junction of the shock
body and end cap.

Make no other suspension
adjustments at this time.
Test ride the snowmobile in
various terrain to fully expe­rience the existing suspen­sion settings before making
adjustments.

Spring Retainer/Adjustment Nut

Shock Body/End Cap

Junction

47

THE PERFECT FIT

Suspension Quick Set-Up Guide

Step 2: Adjust the rear spring to tune vehicle balance.

After the initial test ride, make adjustments to the rear shock spring to
improve vehicle balance. Increasing preload will increase ski pressure
and result in less weight transfer, flatter cornering and more precise
steering response. Decreasing preload will decrease ski pressure and
result in more weight transfer, or less weight on the skis when accelerat­ing.

Step 3: Adjust shock clickers for ride quality.

After making spring adjustments, adjust shock clickers to control bot­toming. Turning a clicker counter-clockwise decreases damping for a
softer ride. Turning a clicker clockwise increases damping for a stiffer
ride and less bottoming.

NOTICE: Always adjust the clicker at least one click below full stiff (full clock-

wise) or shock damage will occur.

Test ride the snowmobile and continue making spring and clicker
adjustments until you achieve the perfect ride.

TIP:Initially, heavier riders may want to set the shock clickers 2-4 clicks higher

than lighter riders.

Ride Experience Adjustment

Too much weight transfer

•Ski pressure is too light

•Skis push

Turn rear shock spring
retainer clockwise (see
page 55)

Too little weight transfer

•Ski pressure is too heavy

•Steering is heavy

Turn rear shock spring
retainer counter-clockwise
(see page 55)

Ride Experience

Clicker

to Adjust

Adjustment

See

Page

Bottoming in the IFS IFS shock - after

150 mi. (240 km)
break-in

Clockwise 52

Bottoming in the center Front track shock Clockwise 54
Bottoming in the rear Rear shock Clockwise 55
No bottoming, but ride is

harsh in front or rear

IFS shock (after
break-in), Front
track shock, Rear
shock

Counter-clockwise 52

54
55

Harsh in chatter/bumps Front track shock,

Rear shock

Counter-clockwise 54

55

48

THE PERFECT FIT

Suspension Quick Set-Up Guide

Accessory rear shock springs are available for riders of different
weights. A corresponding gauge is available for each spring type.

The gauge provided with your snowmobile is calibrated for the stock
spring, which should be used by most riders. Do not change springs
unless your weight is at the very high or very low end of the stock spring
rider weight range and adjustments to the factory-installed spring have
not perfected your ride.

In the following spring guide, the dimension is as measured from the
spring retainer to the junction of the shock body and end cap. See page

46.

Spring Guide

Stock Spring

Accessory

120 Spring

Accessory
260 Spring

See your POLARIS dealer to order an accessory

spring and the gauge calibrated for that spring.

Rider

Weight Dimension

Rider

Weight Dimension

Rider

Weight Dimension

lbs.

kg in. cm lbs. kg in. cm lbs. kg in. cm

120

54 1.5

Min

3.81 90 41 2.375 6.03 240 109 2.125 5.40
130 59 95 43 2.5 6.35 255 116 2.25 5.72
140

64

1.75 4.44

100 45 2.625 6.67 270 122 2.375 6.03

150

68 105 48 2.75 6.99 280 127 2.5 6.35

160 73

2.0 5.08

110 50 2.875 7.3 295 134 2.625 6.67

170

77 115 52 3 7.62 310 141 2.75 6.99

180

82

2.125 5.39

120 54 3.125 7.94 320 145 2.875 7.3

190 86 125 57 3.25 8.26 335 152 3

Max

7.62

200

91

2.25 5.71

130 59 3.375 8.57 - ---

210

95 135 61 3.5 8.89 - ---

220 100

2.50 6.35

140 64 3.625 9.21 - ---

230

104 150 68 3.75 9.53 - ---

240

109

2.75
Max

6.98

155 70 3.875

Max

9.84 - ---

260 118 - -------

49

THE PERFECT FIT

Suspension Quick Set-Up Guide

POLARIS recommends that riders use this Quick Set-Up Guide to make
any adjustments for rider weight and trail conditions. If additional tun­ing is needed after you have exhausted all possible adjustments to the
rear shock spring and clicker, refer to the information on the following
pages of this manual.

Factory Suspension Settings

IFS and Front Track Shock

IFS Shock Clicker 6 clicks clockwise from full soft
IFS Shock Spring Preload From body end to spring:

FOX shocks 3.75 inches (9.52 cm)

PRO-R shocks 3.00 inches (7.62 cm)
Front Track Shock Clicker 2 clicks clockwise from full soft
Front Track Shock Spring Preload 1.375 inches (3.49 cm) from body end to

spring

Stock Rear Spring

Rear Shock Clicker 4 clicks clockwise from full soft
Rear Shock Spring Preload See Optional Spring Guide (page 48)

Accessory Spring Recommended Initial Settings

Accessory 120 Rear Spring

Rear Shock Clicker 4 clicks clockwise from full soft
Rear Shock Spring Preload See Optional Spring Guide (page 48)

Accessory 260 Rear Spring

Rear Shock Clicker 4 clicks clockwise from full soft
Rear Shock Spring Preload See Optional Spring Guide (page 48)

50

THE PERFECT FIT

Front Suspension Adjustments

Independent Front Suspension (IFS)

Factory settings, combined with user adjustments to the rear shock
spring, should be all that’s necessary to provide the best riding experi­ence for most riders. If all rear shock spring adjustments have been
exhausted and rider weight is at the very high or very low weight range
for the stock spring, additional adjustments are possible to the IFS.

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

Break in the suspension for about 150 miles (240 km) before making
adjustments to the front suspension.

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. A-arms

IFS Adjustment Options

• Front shock spring preload

• Compression damping

• Optional springs

• Optional shock valving

1

2

3

4

51

THE PERFECT FIT

Front Suspension Adjustments

IFS Shock Spring Preload

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

Always perform shock spring preload
adjustments with the weight of the vehicle
removed from the shock and with the shock
at full extension.

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

Increasing the spring preload too much
may adversely affect the handling of the
snowmobile and the performance of the
suspension. Never exceed one inch (2.54
cm) of preload beyond the factory settings.

NOTICE: When decreasing preload, make sure at least two turns of preload are

holding the spring between the retainer on the top of the shock and
the threaded spring preload adjuster nut on the shock body. Failure to
do so could cause the retainer to fall off when the suspension is fully
extended.

TIP:Other spring options are available. Please see your POLARIS dealer.

Initial IFS Preload Setting

(from body end to spring)

FOX shocks 3.75 inches

(9.5 cm)

PRO-R premium shocks 3.00 inches

(7.6 cm)

Measure

here

52

THE PERFECT FIT

Front Suspension Adjustments

IFS Shock Compression Damping

Make adjustments to the shock clickers to control bottoming. Make the
adjustments in 1-to-2-click increments, then test ride. Repeat the adjust­ment until the desired result is achieved.

TIP:Initially, heavier riders may want to set the shock clickers 2-4 clicks higher

than lighter riders.

The standard clicker setting is 6 clicks
from the softest position.

• Turn the clicker clockwise for a
stiffer ride (as viewed from the top).

• Turn the clicker counter-clockwise
for a softer ride.

When adjusting, we recommend that
you turn the clicker only one or two
clicks, then test ride. Always adjust
both shocks equally.

Shock Valving

Some shocks can be revalved if spring
preload alone isn't sufficient and fur­ther adjustment is desired to control
suspension stiffness. Please see your
POLARIS dealer.

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

Softer

Ride

Stiffer

Ride

53

THE PERFECT FIT

Rear Suspension Adjustments

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

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

Additional adjustments should be made after initial setup. Make adjust­ments to one area at a time so you can evaluate the change. For further
assistance, see your dealer.

Suspension Performance Tips

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

load should be set. However, this may vary with riding style. With a
little experimentation, each rider can find a preferred set-up.

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

worn rail slide. It can also improve top speed.

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

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

Track Tension

Track adjustment is critical for proper handling. Always maintain cor­rect tension and alignment. Refer to the track tension maintenance sec­tion beginning on page 106.

54

THE PERFECT FIT

Rear Suspension Adjustments

Front Track Shock Compression Damping

Make adjustments to the shock
clicker to control bottoming. Make
the adjustments in 2-click incre­ments, then test ride. Repeat the
adjustment until the desired result
is achieved.

TIP:Initially, heavier riders may want

to set the shock clickers 2-4 clicks
higher than lighter riders.

The standard clicker setting is 2
clicks from the softest position.

• Turn the clicker clockwise for a
stiffer ride.

• Turn the clicker counter-clockwise for a softer ride.

Front Track Shock Spring Preload

Always perform shock spring preload adjustments with the weight of
the vehicle removed from the shock and with the shock at full extension.

Increasing spring preload will decrease ski-to­ground pressure. Decreasing spring preload
will increase ski-to-ground pressure.

The initial preload setting is 1.375 inches
(3.49 cm) from body end to spring. To change
shock spring preload, grasp the spring retainer
and rotate it.

Increasing the spring preload too much may
adversely affect the handling of the snowmo­bile and the performance of the suspension.
Never exceed one inch (2.54 cm) of preload
beyond the factory settings.

When decreasing preload, make sure at least two turns of preload are
holding the spring between the retainer on the top of the shock and the
threaded spring preload adjuster nut on the shock body. Failure to do so
could cause the retainer to fall off when the suspension is fully
extended.

TIP:Other spring options are available. Please see your POLARIS dealer.

Stiffer

Softer

55

THE PERFECT FIT

Rear Suspension Adjustments

Rear Shock Spring Preload Settings

Make adjustments to the rear shock spring to tune vehicle balance.
Always perform shock spring preload adjustments with the weight of
the vehicle removed from the shock and with the shock at full extension.

Increasing preload will increase ski pressure and result in less weight
transfer and flatter cornering and more precise steering response.
Decreasing preload will decrease ski pressure and result in more weight
transfer, or less weight on the skis when accelerating.

Turn the spring retainer up to one turn from the initial setting, then test
ride. Repeat the adjustment in one-turn increments until the desired
result is achieved.

Increasing the spring preload too much may adversely affect the han­dling of the snowmobile and the performance of the suspension. Never
exceed one inch (2.54 cm) of preload beyond the factory settings.

When decreasing preload, make sure at least two turns of preload are
holding the spring between the retainer on the top of the shock and the
threaded spring preload adjuster nut on the shock body. Failure to do so
could cause the retainer to fall off when the suspension is fully
extended.

Rear Shock Clicker

Make adjustments to the shock
clicker to control bottoming, chatter
and general riding comfort. Make
the adjustments in 2-click incre­ments, then test ride. Repeat the
adjustment until the desired result is
achieved.

TIP:Initially, heavier riders may want to

set the shock clickers 2-4 clicks
higher than lighter riders.

The standard clicker setting is 4
clicks from the softest position.

• Turn the clicker clockwise for a

stiffer ride.

• Turn the clicker counter-clockwise for a softer ride.

Stiffer

Softer

56

THE PERFECT FIT

Handlebar Adjustments

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 for-

ward or rearward to the
desired position.

3. Tighten the bolts. Torque

the bolts to 13-16 ft. lbs.
(18-22 Nm).

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. Be

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

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

could damage the handwarmers.

• Right control torque: 27 in. lbs. (3.05 Nm) +/- 10%.

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

3. Tighten the bolts. Torque the bolts to 13-16 ft. lbs. (18-22 Nm).

Loosen top bolts to adjust
handlebar angle

Loosen bottom bolts to
adjust handlebar position

57

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, internal engine components and exhaust systems. Exhaust
systems are critical safety areas that must use approved POLARIS parts.
Please see your POLARIS dealer for service.

58

THE PERFECT FIT

Traction Products

Studs

The track is not warranted by POLARIS if studs have been installed.
Track warranties are also void if track damage or failure results from the
use of any non-POLARIS traction products. Use only POLARIS­approved traction products on your snowmobile.

If you choose to install studs, stud length must not exceed 1.45 inches
(37 mm) for a factory-installed track.

See your dealer about installing studs and/or carbides.

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

strips may result in cooler or tunnel damage. See page 59.
Never add shims to the wear strip. Track damage will result because

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

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

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

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

NOTICE: Aggressive studding patterns may require grinding protruding stud

bolts flush to prevent idler wheel damage. Maintain track tension on
studded tracks on the tight side of the spec to prevent heat exchanger
damage. The center of the stud must be at least 1 1/8 inches (2.9 cm)
from the outside edge of the track.

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

59

THE PERFECT FIT

Traction Products

Carbide Skags

A skag is a replaceable bar attached to the underside of the ski to assist
in turning the snowmobile and to prevent ski wear caused by contact
with roads and other bare terrain. Use carbide skags with studded tracks
to help maintain proper vehicle steering and control. See page 111.

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

Wear Strips

To avoid excessive tunnel wear, tunnel wear strips must be installed
whenever track studding is used. Wear strips are designed for a specific
stud length.

See your dealer's studding chart for recommended traction accesso­ries.

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

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

60

PRE-RIDE INSPECTIONS

Pre-Ride Checklist

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

Item See Page

Drive Belt Condition 101
Steering System 65
Recoil Rope 65
Coolant Level 91
Chaincase Oil Level 86
Injection Oil Level 73
Parking Brake Lock/Brake Lever/Brake System 63, 64, 96
Auxiliary Shut-Off Switch (Engine Stop Switch) 66
Ignition Switch 66
Headlight/Taillight/Brakelight 66
Suspension Mounting Bolts 61
Skags (Wear Bars) 111
Ski Saddle and Spindle Bolts 61
Hood and Side Panel Fasteners 85
Throttle Lever/Safety Switch 74, 75
Rear Wheel Idler Bolts 107
Tether Switch/Strap (if equipped) 66
Track Alignment/Condition 65, 108
Rail Slide Condition 112

61

PRE-RIDE INSPECTIONS

Pre-Ride 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 See Page

Check suspension mounting bolts for tightness. See Dealer
Check rear idler wheel bolts for tightness. 107
Check rear idler adjusting bolt locknuts for tightness. -­Check front torque arm limiter strap condition. -­Check rail slide condition. 112
Check track tension. 106
Check ski runner/skag condition. 111
Check ski spindle bolts for tightness. 109
Check tie rod end nuts for tightness. --

62

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, damag ed, or malfu nctioning
components could result in serious injury or death. Never start the engine
without checking all vehicle components to be sure of proper operation.

Read and Understand Your Owner's Manual

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

Throttle Lever

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

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

Throttle Safety Switch

T est the throttle safety switch system before the snowmobile is operated.
See page 74.

63

PRE-RIDE INSPECTIONS

Before Starting the Engine

Brakes

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

Brake Lever Travel

Squeeze the brake lever. It
should move no closer to the
handgrip than 1/2 inch (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 98 or
see your dealer for service.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 97.

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

1/2” (1.3 cm)

64

PRE-RIDE INSPECTIONS

Before Starting the Engine

Parking Brake Lever Lock

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

1. Brake Lever

2. Parking Brake Lever Lock

3. Master Cylinder Reservoir/ Cover

4. Fluid Level Indicator

Lock Engagement

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

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

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

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

Lock Release

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

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

1

2

3

4

65

PRE-RIDE INSPECTIONS

Before Starting the Engine

Steering System

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

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

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

Track

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

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

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

Side Panel Fasteners

The side panels of the snowmobile protect the operator from moving
parts. Never operate the snowmobile with the side panels open or
removed.

Seat Latches

If your snowmobile is equipped with a removable seat, ensure that the
seat is properly installed and securely latched before each use of the
snowmobile.

Recoil Rope

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

66

PRE-RIDE INSPECTIONS

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 62.

Engine Stop Switch

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

Ignition Switch

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

Tether Switch (if equipped)

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

Lighting

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

Mirrors (if equipped)

Adjust the mirrors so they can be used to their full advantage.

Operating Area

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

67

OPERATION

Starting the Engine

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

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

1. Turn the key to the ON position.

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

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

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

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

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

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

snap back into the housing. Damage may result.

5. If the engine does not start after several attempts, slightly depress

the throttle (no more than 1/4 inch (6 mm) open) while cranking the
engine. When the engine starts, immediately release the throttle.

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

NOTICE: Operating the vehicle immediately after cold starting could cause

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

Restarting an Engine

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

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

2. Turn the key to the OFF position.

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

open position.

4. Crank the engine several times to draw fresh air through the engine.

5. Release the throttle.

6. Restart the engine using the normal starting procedure.

68

OPERATION

Break-In Period

Engine Break-In

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

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

See page 116 for the part numbers of POLARIS products.
Never mix brands of oil. Serious chemical reactions can cause injection

system blockage, resulting in serious engine damage. Oils may also be
incompatible and the result could be sludge formation, filter blockage,
and reduced cold weather flow rates. All POLARIS oils are compatible
with each other.

Initial Fuel Premix

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

Oil Recommendations

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

Fuel VES 2-Cycle Oil Ratio

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

69

OPERATION

Break-In Period

Engine Break-In

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

NOTICE: Use of any lubricants other than those recommended by POLARIS

may cause serious engine damage. We recommend the use of
POLARIS lubricants for your vehicle.

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

Oil Injection System

Always check and fill the oil bottle when refueling. See page 73.

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

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

Drive Belt Break-In

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

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

70

OPERATION

Track Warm-Up

WARNING! A loose track or flying debris could cause seriou s injury or death.

Stand clear of the front of the snowmobile and the moving track. Never hold the
snowmobile up or stand behind it while warming up the track. Do not use
excessive throttle during warm-up or when the track is free-hanging. Use a
stable rear support.

WARNING! Use of traction products such as studs 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. Never rotate a dry track. For best track performance, always lubri-

cate the track with water or snow before rotating the track.

2. Use an appropriate stand to securely support the rear of the snow-

mobile at the rear bumper. The track should be about 4 inches (10
cm) off the ground.

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

4. 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.

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

the snowmobile to the ground.

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

to loosen snow and ice.

Slide Rail and Track Cooling

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

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

71

OPERATION

Fuel

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

• Always tu rn off the engine 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 refu-

eling is performed or where gasoline is stored.

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

and water and change clothing.

• Never start the engine or let it run in an enclosed area. Engine exhaust fumes

are poisonous and can cause loss of consciousness or death in a short time.

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

WARNING

WARNING

72

OPERATION

Fuel Recommendation

For peak performance, POLARIS recommends the use of 91 octane fuel
or higher. Although 87 octane fuel is usable, some engine performance
will be lost and fuel economy will decrease. Do not use lower than 87
octane fuel. Do not use fuel containing more than 10% ethanol. Never
use E85 fuel in your snowmobile.

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

damage. Perform maintenance as recommended.
Prolonged exposure to petroleum based products may damage paint.

Always protect painted surfaces when handling fuel.

Fuel System Deicers

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

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

73

OPERATION

Oil

Low Oil Level

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

1. Immediately stop the engine if the

low oil indicator light comes on.

2. Open the left side panel.

3. View the oil level in the oil bottle.

4. Add oil as needed before operating.

NOTICE: Operating the snowmobile without adequate engine lubrication can

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

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

“Add”

Mark

74

OPERATION

Engine Stop Switch

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

Throttle Safety Switch

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

WARNING! Operating the snowmo bile with a faulty throttle safety switch can
result in serious injury or death in the event of an accident. If the throttle safety
switch does not shut off the engine during a carburetor/throttle system
malfunction, immediately push down the engine stop switch. Do not start the
engine again until the malfunction has been corrected by your dea ler.

Test the throttle safety switch
system daily before operation.

1. Sit on the seat.

2. Start the engine and allow it

to idle.

3. Hold the throttle lever pin

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

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

must shut down the engine.

x

75

OPERATION

Throttle Lever

WARNING! An improperly functioning throttle lever may cause erratic

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

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

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor/throttle body to

determine what caused the safety switch to activate.

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

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

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

go through normal starting procedures.

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

POLARIS dealer for service.

Excessive freeplay in the throttle cable may cause the safety switch to
activate, preventing the engine from starting. If this occurs, return the
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.

76

OPERATION

Emergency Stopping

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

SYSTEM WHAT IT DOES

Ignition Switch Interrupts ignition circuit
Brake Slows jackshaft
Engine Stop Switch Interrupts ignition circuit
Throttle Safety Switch Interrupts ignition circuit
Tether Switch (Option) Interrupts ignition circuit

77

OPERATION

Electronic Reverse (PERC)

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

• Shift to or from reverse only when the snowmob ile is stopped and when

engine speed is at idle.

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

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

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

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

WARNING

78

OPERATION

Electronic Reverse (PERC)

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

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

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

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

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

restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

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

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

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

ward.

79

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 inches (10 cm) off the ground.

Remove the key and cover the snowmobile.

Towing

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

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

WARNING! Braking distances increase when towing loads. Slow do wn 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: T owing a disabled snowmobile with the drive belt in place can result in

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

80

MAINTENANCE

Emission Control Information

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

Emission Control Label

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

Emission Control Maintenance Requirements

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

Owner's Responsibilities

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

Non-ionizing Radiation

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

81

MAINTENANCE

POLARIS Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow
recommended regular maintenance and perform service checks as out­lined in this manual. Record maintenance and service in the Mainte­nance Log beginning on page 134.

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.

82

MAINTENANCE

Periodic Maintenance Interval Table

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

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

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CLUTCH

Clutch Alignment Offset
(without belt)

100 III

Drive Belt Condition 101 IIII
Clutches 100 CCC
Belt Tension -- IIII
Clutch Sheaves 100 IIII

ENGINE/COOLING

Engine Mounts 84 IIII
Recoil Rope -- IIII
Cylinder Head Bolts -- III
Cylinder Base Nuts -- III
Ignition Timing BTDC -- III
VES System -- CCC I
Coolant Level 91 IIRI
Coolant Hose -- IIII
Coolant Circulation -- III
Coolant Leaks -- IIII
Spark Plugs 89 IIRI
Exhaust Pipe 94 II
Exhaust Retaining

Springs

94 IIII

83

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

BRAKES

Hose Routing -- IIII
Hose Condition -- IIII
Fluid Leaks -- IIII
Brake Pads 96 IIII
Brake Disc -- IIII
Parking Brakes 64 IIII
Brake System 63, 96 I
Brake Fluid 97 I

FUEL MANAGEMENT

Idle RPM -- III
Throttle Lever 75 III II
Oil Pump Lever

(synchronize)

-- III

Throttle Position Sensor -- III
Fuel Lines 87 IIII
Fuel Filter Replacement 87 EVERY 2000 (3200) or EVERY 2 YEARS
Oil Filter 90 R
Oil Lines 90 III
Air Box -- III II

ELECTRICAL

Auxiliary Shut-Off
Switch

66 II I II

Throttle Safety Switch 74 III II
Ignition Switch -- III II
Taillight 66 III II
Brakelight 66 II I II
Headlight 66 II I II

84

MAINTENANCE

Periodic Maintenance Interval Table

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

Bolt Torque Inspection

To maintain proper chassis performance, see your POLARIS dealer for
a bolt torque inspection every 1000 miles (1600 km).

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CHASSIS

Ski Toe Alignment -- II I
Suspension Mounting

Bolts

-- III II

Bolt Torques See your dealer every 1000 mi. (1600 km) for inspection
Steering Fasteners -- III IC
Rear Suspension

Fasteners

-- III II

Rear Suspension
Bushings

112 III

Suspension Shock Oil -- R
Rear Shock Threads 85 L
Cooling Fins and

Shroud

-- IIII

Skags (Wear Bars) 111 III II
Ski Saddle/Spindle Bolts -- III II
Drive Chain Tension 95 III I I
Hood and Side Panel

Fasteners

85 II I II

Rear Wheel Idler Bolts 107 III II
Idler Bolt Jam Nut 107 III II
Rear Suspension Pivot

Shaft

112 LL L

Camber Alignment -- III
Handlebar Centering -- I
Tether Switch and Strap 66 II I II
Track Tension 106 III II
Track Alignment 108 III II
Front Limiter Strap -- III II
Rail Slide Condition 112 I
Chaincase Oil 86 IRI RI

Item Description

Engine Mounting Bolts Remove drive clutch and resonator for access to all bolts
Chaincase Mounting Bolts Two (2) TORX-head bolts on forward side of chaincase

Four (4) rear chaincase nuts

85

MAINTENANCE

Hood/Side Panel

The hood and side panels of the
snowmobile protect the operator
from moving parts. Never operate
a snowmobile with the side panels
open or removed. Always ensure
that the hood and side panels are
securely in place before starting
the engine.

To open a side panel, rotate the
two 1/4-turn fasteners at the upper
edges of the side panel. Release
the side panel strap at the lower
edge of the panel.

T o remove an open side panel, pull
the panel outward to release the
tabs at the lower edge of the panel.

Removing the hood is not recommended. Any service requiring the
removal of the hood should be performed by an authorized POLARIS
dealer.

Lubrication

Rear Shock Body Threads

Lubricate rear shock body threads
seasonally with a low-temperature
synthetic grease.

Driveshaft Bearing

This model has sealed bearings that
require no additional lubrication.

Strap

1/4-Turn Fasteners

Threads

86

MAINTENANCE

Lubrication

Chaincase Oil

Check and change the chaincase oil at the intervals outlined in the main­tenance charts beginning on page 81. Maintain the oil level at the top of
the fill plug hole. POLARIS recommends the use of POLARIS Syn­thetic Chaincase Lube. See page 116 for the part numbers of POLARIS
products.

Oil Level

1. Position the vehicle on a level

surface.

2. Remove the fill plug.

3. Using a funnel, slowly add the

recommended oil until the fluid
begins to overflow.

4. Wipe the fill area with a clean

cloth.

5. Reinstall the fill plug. Torque to

6-10 ft. lbs. (8-13 Nm).

Oil Change

1. Position the vehicle on a level surface.

2. Place a drain pan under the drain plug. Remove the drain plug.

Allow the oil to drain completely.

3. Clean off all metal shavings from the plug.

TIP:The sealing surfaces on the drain plug and the oil tank should be clean and

free of burrs, nicks or scratches.

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

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

6. Using a funnel, slowly add the recommended oil until the fluid

begins to overflow. Fluid capacity is 9 oz. (266 ml).

7. Wipe the fill area with a clean cloth.

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

Fill Plug

87

MAINTENANCE

Intake Filters

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

Fuel Pump

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

Fuel Filter/Fuel Lines

See your POLARIS dealer for replacement of the fuel filter at the inter­vals outlined in the Periodic Maintenance Table beginning on page 81.

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

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

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

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

Foam Filters

88

MAINTENANCE

Spark P lugs

Spark Plug Recommendations

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 at the intervals outlined in the Periodic Mainte­nance Table beginning on page 81. Refer to the specifications section
for the specific spark plug to be used in your snowmobile.

• 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.

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

damage. A spark plug with a heat range too high will always cause
engine damage if the engine is operated in conditions more severe
than intended for that plug. Always use the spark plugs recommended
for your snowmobile. Refer to the specifications section beginning on
the page 122.

89

MAINTENANCE

Spark P lugs

Spark Plug Inspection

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.

1. Remove the left side panel.

2. Remove the spark plug cap.

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

spark plug counter-clockwise to remove.

4. Reverse the procedure for spark plug installation. Torque to specifi-

cation.

5. Reinstall the spark plug cap.

Spark Plug Condition

Normal 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.

Wet Fouled Plug

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

90

MAINTENANCE

Oil Lines

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

Oil Filter

Please see your dealer for replacement of the in-line oil filter every 2000
miles (3200 km) as outlined in the maintenance charts beginning on
page 81.

91

MAINTENANCE

Cooling System

Coolant

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

When adding or changing coolant, POLARIS recommends using
POLARIS Antifreeze 60/40 Premix. POLARIS Antifreeze is already
premixed and ready to use. Do not dilute with water. Never exceed a
60% antifreeze/40% water mixture. See page 116 for POLARIS prod­ucts.

Never add tap water to the cooling system. Minerals cause deposits and
may react adversely with the metals in the engine and cooling system.

Coolant Level

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

• Coolant bottle/overflow tank

• Pressure cap

• Connecting hoses
Always maintain the coolant level at or

slightly above the FULL COLD mark on
the coolant bottle (when the engine is
cold).

1. Stop the engine.

2. Open the right side panel.

3. View the coolant level in the coolant

bottle.

4. Add coolant as needed.

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

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

“Full Cold” Mark

92

MAINTENANCE

Cooling System

Engine Overheating

The over-temperature indicator on the
instrument cluster will illuminate when the
engine is overheating. The indicator will
flash when engine temperature reaches
critical levels.

Illuminated Indicator

Take action to cool the engine:

• Drive in loose snow.

• View the coolant level. Do not open the
pressure cap while the engine is hot.
Add coolant if the level is low.

• Stop the engine and allow it to cool down.

If you must continue to operate while the indicator light is illuminated,
drive slowly and stop the engine frequently to allow it to cool down.

Flashing Indicator

If the indicator flashes, continued operation could result in serious
engine damage. The system will automatically reduce engine power and
create a misfire condition. Stop the engine immediately. Allow the
engine to cool down.

If engine overheating seems to be caused by something other than poor
cooling conditions, see your dealer for service.

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.

93

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: Severe engine damage may occur if the cooling system becomes

restricted or plugged or contains trapped air pockets.

Peform this procedure in a well-ventilated area. Use the recommended
coolant. See page 91.

1. Open the side panels and remove the hood.

2. Close the side panels.

WARNING! Never operate a snowmobile with the side panels open or removed.

3. Position the vehicle with the right ski and control arms elevated at a

45-degree angle.

4. Fill the coolant bottle to the COLD FILL mark.

5. Using an 8mm wrench, loosen the air bleed screw located on the top

of the coolant outlet elbow. Use a shop towel to catch any coolant
that leaks from the bleeder. Tighten the screw after a steady stream
of coolant flows from the bleeder.

6. Fill the coolant bottle to the COLD FILL mark.

7. Install the coolant bottle cap to the first lock. Do not tighten to the

fully seated position.

8. Lock the parking brake.

9. Start the engine and run at a fast idle for several minutes, until the

heaters are warm to the touch. Loosen the bleed screw occasionally
to purge any trapped air.

10. When all heater extrusions are warm to the touch, stop the engine.

11. Allow the engine and cooling system to cool.

12. Fill the coolant bottle to the COLD FILL mark.

13. Carefully lower the front end of the snowmobile.

14. Secure the bleed screw and reinstall the pressure cap.

15. Open the side panels and reinstall the hood. Close the side panels.

94

MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at approximately 2000
miles (3200 km). Always allow the engine and exhaust system to cool
completely before inspecting.

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

1. Open the side panels and remove the hood. See page 85.

2. Inspect the muffler and pipes for cracks or damage.

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

grommets.

4. Check for loose clamps on the pipe covers.

5. Reinstall the hood and side panels.

95

MAINTENANCE

Drive Chain Tension

Check drive chain tension at the intervals outlined in the maintenance
charts beginning on page 81 and before each long trip.

1. Remove the side panels.

2. Rotate the driven clutch coun-

ter-clockwise to move all
chain slack to the tensioner
side. Lock the brake lever
lock, or have an assistant hold
the brake lever firmly.

3. Loosen the adjuster bolt jam

nut.

4. Finger tighten the adjuster bolt

until it can no longer be
adjusted by hand, then back
off 1/4 turn.

5. Tighten the jam nut while

holding the adjuster bolt.
Torque to 21 ft. lbs. (28 Nm).

6. Reinstall the side panels.

7. Release the brake lever lock.

Jam

Nut

Adjuster

Bolt

96

MAINTENANCE

Brakes

Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See
page 63.

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

WARNING! Brake failure during operation can result in serious injury or death.
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 inch or 1.5 mm).

Brake Components

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material (Replace when

thickness is less than 1/16 inch/1.5
mm).

Excessive Lever Travel

Hydraulic brakes are self-adjusting, but if
excessive brake pad clearance develops,
bring the snowmobile to an authorized
POLARIS dealer for inspection and
adjustment.

2

1

3

97

MAINTENANCE

Brakes

Brake Fluid

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.

Replace brake fluid at least every two years with POLARIS DOT 4 high
temperature brake fluid. See page 1 16 for the part numbers of POLARIS
products.

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 labels, paint and some plastics. Always wipe

up spills immediately.

98

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 the 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 inch (.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 cylinde r 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 97.

8. Reinstall the gasket and cover.