Polaris 600 Switchback Assault 144 User Manual

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600 SWITCHBACK ASSAULT

800 SWITCHBACK ASSAULT

Snowmobile Owner's Manual

for Maintenance and Safety

IMPORTANT NOTICE TO OWNER

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

code with your smartphone.

Modifications to this snowmobile are not recommended

and may result in voided warranty coverage. Please

read the warranty section of this manual carefully.

WARNING

Read, understand, and follow all of the instructions and safety

precautions in this manual and on all product labels.

Failure to follow the safety precautions

could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth defects

or other reproductive harm.

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our 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

• RZR® sport 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.

POLARIS®, PERC®, SWITCHBACK® and ASSAUL T® are trademarks of POLARIS Industries Inc.

Copyright 2015 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

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

Printed in U.S.A. 2016 600/800 SWITCHBACK ASSAULT Owner's Manual P/N 9925995

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

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

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 52

This section includes suspension set-up information 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 118

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 124

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 125

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 137

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

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.

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.

INTRODUCTION

Tunnel VIN

Certification Label

Emissions Certification Label

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.

NOTICE: If installing an aftermarket tunnel wrap, do not cover the tunnel

certification, tunnel VIN or emissions certification labels with the wrap. If the tunnel wrap doesn’t provide an opening for these labels, remove the section of wrap where the labels are located.

Vehicle Model Number: ___________________________________________________

Tunnel VIN (right side of tunnel): ____________________________________________

Engine Serial Number (on recoil housing): _____________________________________

Key Number: _____________________ _______________________________________

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 hazard.

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 which, if not avoided, could result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, 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.

SAFETY

WARNING

Operator Safety

Follow the recommended maintenance program beginning on page 83 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.

SAFETY

NO STEP

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.

SAFETY

Operator Safety

Riding Apparel

Helmet

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

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

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

Eye Protection

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

Clothing

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

051039

0006.31

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

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.

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.

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.

SAFETY

Operator Safety

Ice and Snow Build-up

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

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

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

Driving 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 WARNING! Inadequate cool ing 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.

the slide rail, track and/or engine.

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.

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 crossi ng 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.

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

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

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.

damage to the engine.

removed.

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.

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.

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WINDCHILL CHART (°F)

Wind

Speed

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

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

5 3631251913 7 1 -5-11-16 10 34 27 21 15 9 3 -4 -10 -16 15 32 25 19 13 6 0 -7 -13 20 30 24 17 11 4 -2 -9 -15 25 29 23 16 9 3 -4 -11 -17 30 28 22 15 8 1 -5 -12 35 28 21 14 7 0 -7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89 40 27 20 13 6 -1 -8 -15 45 26 19 12 5 -2 -9 -16 50 26 19 12 4 -3 -10 -17 55 25 18 11 4 -3 -11 60 25 17 10 3 -4 -11

Frostbite in >>

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

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

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

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

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

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

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

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

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

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

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

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

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

30 min. 10 min. 5 min.

WINDCHILL CHART (°C)

Wind

Speed

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

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

8 3 0 -4 -7 -11 -14 -18 -22 -25 -29 16 2 -2 -6 -10 -13 -17 -21 -24 -28 24 1 -3 -7 -11 -15 -19 -22 -26 32 0 -4 -8 -12 -16 -20 -24 -28 40 -1 -5 -9 -13 -17 -21 -25 -29 48 -1 -5 -9 -13 -18 -22 -26 56 -2 -6 -10 -14 -18 -22 -26 64 -2 -6 -10 -15 -19 -23 -27 72 -2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74 80 -3 -7 -11 -15 -20 -24 -28 88 -3 -7 -12 -16 -20 -24 96 -3 -8 -12 -16 -21 -25

Frostbite in >>

Actual Thermometer Reading (°C)

Equivalent Temperature (°C)

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

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

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

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

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

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

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

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

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

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

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

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

30 min. 10 min. 5 min.

SAFETY

Clutch Warning/Belt Removal

Safety Labels and Locations

W arning labels have been placed on the 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/Belt Removal

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.

BELT REMOVAL - ALL UNITS

1. For electric reverse models, engine must be stopped in forward to allow clutch opening.

2. Install L-wrench from the tool kit into the open threaded hole in the driven clutch.

3. Turn the L-wrench clockwise to open the sheaves and replace the belt. Return the L-wrench to the tool kit.

SEE OWNER’S MANUAL FOR SHEAVE WIDTH ADJUSTMENT PROCEDURE.

7176327

SAFETY

Reverse Warning

“No Passenger” Warning/Fuel

Recommendation Label

Safety Labels and Locations

“No Passenger” Warning/Fuel Recommendation Label

Snowmobiles designed for a single rider only have a NO PASSENGER warning label on the console:

WARNING

This vehicle is designed for operator only. NO PASSENGER

FUEL RECOMMENDED 91+ OCTANE WITHOUT

ETHANOL For maximum performance

see decal on left hand side panel for proper gauge setting.

7178713

Reverse Warning

The reverse warning label is located on the console:

WARNING

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

• Look behind before and while backing up.

• Avoid sharp turns.

• Shift to or from reverse only when stopped.

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

If electric reverse:

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

• Push button again to return to forward.

SAFETY

Track

Warning

Hot Surface

Warning

Safety Labels and Locations

Track Warning

The track warning label is on the rear tunnel:

WARNING

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

7172519

Hot Surface Warning

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

WARNING Hot Surface Do Not Touch

Burns may result. Entire top of tunnel may be hot. Install only accessories specifically approved for this model by POLARIS.

7176164

Pressure Cap Warning

This warning label is found on the pressure cap of applicable liquid cooled models:

WARNING

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

7170063

SAFETY

Operation Warning

Safety Labels and Locations

Operation Warning

The operation warning label is also located on the console.

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.

(continued on next page)

SAFETY

Safety Labels and Locations

Operation Warning

• When operating with a passenger (on approved models only) reduce speed

and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle.

• When operating on hard-packed snow, ice, or when crossing roads, steering

and braking ability are greatly reduced. Reduce speed and allow extra space to turn or stop.

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

a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products.

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

ability.

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

engaged for more than five minutes.

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

tion. 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.

FEATURES

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. Snow Flap

12. Suspension

13. Track

14. Side Panel

15. Side Panel Strap

16. Side Panel Fasteners

FEATURES

13 12 11

1. Fuel Filler Cap

2. Electronic Reverse Button

3. Brake Lever

4. Parking Brake Lock

5. Standard Instrument Cluster

6. Ignition Switch

7. Engine Stop Switch

8. Throttle Control

9. Recoil Starter Handle

10. Interactive Digital Display (if equipped)

11. Handlebar Grip Warmer Switch

12. Headlight Dimmer Switch

13. MODE/SET Switch

FEATURES

Storage Bag

Storage Bag/Tool Kit

A storage bag and tool kit is located under the left side panel between the oil bottle and console.

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.

Accessories

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

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

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others This applies, but is not limited to the following areas: brakes, clutches,

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

Down

FEATURES

Fuel

Selection

Fuel Type Selection

Whenever using ethanol, MTBE or other forms of oxygenated gasoline, 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.

Standard Instrument Cluster

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.

Fuel Type Selection Label

Interactive Digital Display (IDD)

If your model is equipped with the interactive digital display (IDD), please see your IDD Owner’s Manual for fuel type selection procedures.

FEATURES

IDD Gauge DET Display

NOTE: The IDD alert indicates which

cylinder is experiencing detonation.

Standard Gauge DET Display

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

FEATURES

Detonation Elimination Technology (DET)

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

DET Troubleshooting

Cause of DET Activation Solution

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

resistor installed 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 fo r service Alcohol-based fuel additive used with

Ethanol fuel

Improper engine modifications Do not modify the engine

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 41 for security system activation and operating instructions (standard instrument cluster).

Verify correct fuel resistor for fuel type in tank

Do not add deicers or additives that contain any form of alcohol while using up to 10% Ethanol fuel

If your model is equipped with the Interactive Digital Display (IDD), please see the IDD Owner’s Manual provided with your snowmobile.

FEATURES

Engine Overheat Indicators

Over-Temperature Indicator (Standard Cluster)

The over-temperature indicator on the instrument cluster will illuminate when the engine is overheating. Take action to cool the engine. See page 33.

The indicator will flash when engine temperature reaches critical levels. Stop the engine immediately. See page 33.

Overheat Warning (IDD)

The engine temperature scale at the right side of the IDD screen changes to RED and the check engine temperature indicator at the top left of the screen illuminates when the engine is overheating. Take action to cool the engine. See page 33.

The indicator will flash when engine temperature reaches critical levels. Stop the engine immediately. See page 33.

Please see your IDD Owner’s Manual for more information.

600/800 Models Engine Temperature Protection Modes

Hot Lamp Threshold*

ON Lamp illuminates: Idle = 201° F (94° C), WOT = 185° F (85° C) FLASHING Lamp Flashes, Engine Turns Off: Idle = 215.6° F (102° C),

* Only the minimum (idle) and maximum (WOT) parameters are listed.

WOT = 201° F (94° C)

FEATURES

Engine Overheat Indicators

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.

NOTE: If engine overheating seems to be caused by something other than

Engine-Cooling Actions

If the engine is overheating, promptly take action to cool the engine.

• Drive in loose snow.

• V iew the coolant level. Do not open the pr essur e cap while the engine

• Stop the engine and allow it to cool down.

NOTICE: If you must continue to operate while the indicator light is illuminated,

poor cooling conditions, see your dealer for service.

is hot. Add coolant if the level is low.

drive slowly and stop the engine frequently to allow it to cool down.

FEATURES

Rider Information

Center

Check Engine

Indicator

High Beam

Indicator

Low Oil

Indicator

Over-

Temperature

Indicator

Park Brake

Indicator

Reverse

Indicator

MODE Button

SELECT

Button

Standard 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 or console.

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.

Mode/Set Switch

FEATURES

Standard 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 48 for diagnostic code definitions.

Over-Temperature Indicator

This indicator illuminates to alert the operator that the engine is overheating. T ake action to cool the engine. See page 33. 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 75.

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 transmission is in reverse. See page 79.

FEATURES

Standard 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, 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 40.

FEATURES

Standard 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 38.

2. Speed Display - The speed display area displays either vehicle speed or engine speed. To change the display, see page 38.

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

Trip A, Trip B and engine hours. To change the display, see page 39.

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

low.

5. 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 39.

FEATURES

Standard 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 button or the MODE switch until the desired item is displayed.

FEATURES

Standard 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.

T o 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.

FEATURES

Standard 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.

FEATURES

Standard 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.

FEATURES

Standard 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 control unit (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.

FEATURES

888

Standard 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

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

NOT locked.

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 T ASK 2 through TASK 4 to change the code to one of your own choosing.

FEATURES

Standard 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

alternate 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.

FEATURES

Standard 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.

FEATURES

Standard 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 42. 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

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

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

Displays ENTER CODE (to lock the system)

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)

FEATURES

Standard 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 48 for code definitions and failure descriptions.

FEATURES

Standard Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions

Open Load:

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

Short-to-Ground:

control unit and the item listed in the chart.

Shorted Load:

shorted together, or the item has shorted internally.

Short-to-Battery:

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

Throttle Position Sensor

Vehicle Speed Sensor Data Erratic, Intermittent or Missing 84 2 Intake Air Temperature Sensor Voltage Too High 105 3

Barometric Pressure Sensor

Engine Temperature Sensor

Alternator Power Supply Potential (DC Chassis Voltage)

Exhaust Temperature Sensor Voltage Too High 173 3

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

The wire is shorted to ground between the electronic

The wires leading to the item listed in the chart are

The wire leading from the item listed in the chart to

Diagnostic Codes

Component Condition SPN FMI

Voltage Too High 51 3 Voltage Too Low 4 Abnormal Rate of Change 10

Voltage Too Low 4 Voltage Too High 108 3 Voltage Too Low 4 Voltage Too High 110 3 Voltage Too Low 4 Temperature Too High 16 Engine Overheat Shutdown 0 Temperature Above Normal Range 15 Voltage Too High 167 3 Voltage Too Low 4

Voltage Too Low 4

FEATURES

Standard 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

Knock Level Cylinder 2 (PTO) Maximum Detonation

Sensor Supply Voltage 1 (TPS/ TMAP Sensor Power)

Sensor Supply Voltage 2 (Ground Speed Sensor)

ECU Output Supply Voltage 2 (Injection Supply PWR)

Throttle Release Signal Voltage Too High 520194 3

Chassis Relay Driver Circuit Open/Grounded 520208 5

Exhaust Valve Solenoid Driver Circuit Grounded 520215 5

Fuel Type Selected Voltage Too High 524007 3

Correction Limit Reached

Knock Above Critical Level 16

Correction Limit Reached

Knock Above Critical Level 16

Voltage Too Low 3509 4

Voltage Too Low 3510 4

Voltage Too High 3598 3

Voltage Too Low 4

Throttle Stuck 7

Driver Circuit Short to B+ 3

Voltage Too Low 4

Signal Out Of Range 2

1352 0

1353 0

FEATURES

Display Screen

5-Button

Keypad

Interactive Digital Display (IDD)

The IDD (if equipped) provides the rider with:

• Speedometer

• Tachometer

•Odometer

• 2 Trip Meters

• Fuel Level Indicator

• Coolant T e mperature

• Battery Voltage

• Fuel Type Selection

• Vehicle Security

CAUTION! Use a microfiber hand towel to clean the LCD screen. Certain products will damage the screen and other plastic surfaces. Do not use alcohol to clean the display screen. Immediately clean off any gasoline that splashes on the instrument cluster.

NOTICE: The speedometer may give wrong values at the existence of

The IDD also offers GPS mapping and Bluetooth compatible smartphones/devices. This feature will display text messages and missed phone calls on the display screen.

electromagnetic radiation >= 10 V/m.

® connectivity for

Mode/Set Switch

The IDD sub-menus and most display features are controlled by either the five button keypad on the IDD or by the MODE/SET switch on the left handlebar or console.

Please see your IDD Owner’s Manual for more information.

TIP:The online manual is frequently

updated.

THE PERFECT FIT

Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

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

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

TIP:The rear bumper may need to be

lifted upward slightly to fully extend the suspension.

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

To determine sag, commonly referred to as ride-in, subtract measurement Y from X (Sag=X-Y). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. See illustration.

The ideal amount of sag for this rear suspension is five inches (12.7 cm) (X-Y=5 in./12.7 cm).

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

THE PERFECT FIT

Soft

(long end of cam to front)

Medium

(short end of cam up)

Firm

(long end of cam up)

Stiffer Softer

Rear Track Shock

Front Track

Shock

Suspension Adjustments

Torsion Spring Preload

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

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

Shock Compression Damping

Compression damping can be adjusted at the front suspension and at the rear track shock. Make adjustments in 2-click increments, then test ride. When adjusting the front suspension, always adjust both clickers equally.

To stop bottoming of the front or rear suspension (stiffer ride), rotate the clicker(s) clockwise two clicks (as viewed from the top of the clicker), then test ride. Repeat the adjustment until bottoming stops and the desired ride quality is achieved.

For a more plush ride at the front or rear suspension, rotate the clicker(s) counterclockwise two clicks, then test ride. Repeat the adjustment until the desired ride quality is achieved.

THE PERFECT FIT

Suspension Adjustments

Independent Front Suspension and Front Track Shock Spring Preload

Factory settings, combined with user adjustments to the rear track shock spring, should be all that’s necessary to provide the best riding experience for most riders. The primary adjustment for overall vehicle balance is torsion spring preload. Perform this adjustment first. See page

52. After adjusting torsion spring preload, and if desired, additional

adjustments can be made to the independent front suspension and front track shock preload. springs on both sides of the vehicle 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.

When adjusting the front suspension, be sure the

THE PERFECT FIT

Measure

here

Front Track Shock

Suspension Adjustments

Independent Front Suspension and Front Track Shock Spring Preload

For a softer ride on rough, washboard surfaces, reduce front track shock (FTS) spring preload by 1-2 turns.

NOTICE: When decreasing preload, make sure at

To improve corner stability, increase front suspension (IFS) spring preload by 1-2 turns

on both sides of the vehicle. 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.

Walker Evans Shock 2 inches

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.

Initial Front Track Shock Preload Setting

(from body end to top of the retainer)

(5.08 cm)

THE PERFECT FIT

Measure

here

IFS Shock

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.

Initial IFS Preload Setting

(from body end to top of the retainer)

Walker Evans Shock 3.25 inches

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

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

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.

(8.25 cm)

THE PERFECT FIT

Handlebar Component Fastener Torques

4/5

Component Torque

Do not over-tighten

IMPORTANT: Moving a handlebar component without first loosening its screws/set screws may cut grooves into the handlebar, making it difficult to secure the component. Do not move a handlebar component without first loosening its mounting screws/set screws.

Take care to avoid damaging hand warmer/brake switch wires when moving components.

1. Brake Lever / Master Cylinder

2. Auxiliary Engine Stop Switch Set Screw 12 in-lbs (1.4 Nm)

3. Handlebar Hook Screw Aluminum: 10 ft-lbs (13.5 Nm)

4. Throttle Lever Block Set Screw 27 in-lbs (3 Nm)

5. Throttle Lever Block Cover Screws 6 in-lbs (0.7 Nm)

6. Handlebar Clamp Screws/Bolts 7 ft-lbs (9.5 Nm)

7. PERC Button Screw 35 in-lbs (4 Nm) Hand Guard Mounts (if applicable) Hand-Tight

60-80 in-lbs (6.7-9 Nm)

Steel: 18 ft-lbs (24 Nm)

THE PERFECT FIT

Mounting Screws

Throttle Block

Set Screw

PERC Button

Screw

Cyclone Brake Master Cylinder Alignment

1. Loosen the two mounting screws.

CAUTION! Take care to avoid damaging hand warmer/brake switch wires when moving components.

2. Move the master cylinder to the desired position.

3. Tighten the screws to specification. Torque the front screw (1) first, then torque the screw (2) next to the reservoir. Do not over-torque.

Torque: 60-80 in-lbs (6.7-9 Nm)

Throttle Block Alignment

1. Slightly loosen the set screw on the bottom of the housing.

2. Move the control block to the desired position.

NOTICE: Take care to avoid damaging hand

3. Tighten the screw to specification.

4. With the engine off, test throttle lever movement after tightening the

warmer wires when moving components.

Do not over-torque.

Torque: 27 in-lbs (3 Nm)

screw. See page 77.

PERC Button Alignment

1. Loosen the mounting screw.

2. Move the PERC button to the desired position.

3. Tighten the screw to specification. Do not over-torque.

Torque: 35 in-lbs (4 Nm)

THE PERFECT FIT

Stop Switch

Set Screw

Loosen Clamping

Screw

(do not remove)

Engine Stop Switch Alignment

1. Slightly loosen the set screw on the bottom of the housing.

2. Move the switch to the desired position.

CAUTION! The stop switch must be positioned in an easily accessible location.

3. Tighten the screw to specification. Do not over-torque.

Torque: 12 in-lbs (1.4 Nm)

Handlebar Hook Alignment

1. Slightly loosen the clamping screw. Do not remove the screw.

2. Rotate the hook to the desired position.

3. Tighten the screw to specification. Do not over-torque.

Torque: Aluminum Bars 10 ft-lbs (13.5 Nm) Torque: Steel Bars 18 ft-lbs (24 Nm)

THE PERFECT FIT

Handlebar Adjustments

Handlebar Angle

1. Loosen the four bolts on the top of the adjuster block. If necessary, pry the blocks apart with a screwdriver.

2. Adjust the handlebar forward or rearward to the desired angle.

3. Be sure the handlebar, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right. If necessary , adjust the left and right hand controls. See page 57.

4. Tighten the bolts to specification. Do not over-torque.

Torque: 7 ft-lbs (9.5 Nm)

Loosen

Bolts

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 103 Steering System 65 Recoil Rope 65 Coolant Level 94 Chaincase Oil Level 89 Injection Oil Level 75 Parking Brake Lock/Brake Lever/Brake System 63, 64, 98 Auxiliary Shut-Off Switch (Engine Stop Switch) 66 Ignition Switch 66 Headlight/Taillight/Brakelight 66 Suspension Mounting Bolts 61 Skags (Wear Bars) 1 13 Ski Saddle and Spindle Bolts 61 Hood and Side Panel Fasteners 87 Throttle Lever/Safety Switch 76, 77 Rear Wheel Idler Bolts 109 Tether Switch/Strap (if equipped) 66 Track Alignment/Condition 65, 110 Rail Slide Condition 113

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. -Check rear idler wheel bolts for tightness. 109 Check rear idler adjusting bolt locknuts for tightness. -Check front torque arm limiter strap condition. -Check rail slide condition. 113 Check track tension. 108 Check ski runner/skag condition. 113 Check ski spindle bolts for tightness. -Check tie rod end nuts for tightness. --

PRE-RIDE INSPECTIONS

Before Starting the Engine

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

WARNING! Operating the vehicle with worn, damaged, or malfuncti oning 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 76.

PRE-RIDE INSPECTIONS

Before Starting the Engine

Brakes

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

Brake Lever Travel

Squeeze the brake lever. It should move no closer to the handgrip than 1/2” (1.3 cm). A smaller distance indicates low brake fluid level or air in

(

”

the hydraulic system. Refer to the brake bleeding information on page 100 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 99.

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.

)

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

Lock Release

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

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

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.

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.

Hood and Side Panel Fasteners

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

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.

PRE-RIDE INSPECTIONS

St art 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.

OPERATION

Ignition Switch

The ignition switch has three positions.

OFF Vehicle / IDD power off RUN Vehicle / IDD power on START Activates starter motor (if equipped)

If equipped with electric start, turn the key to START to crank the engine. When the key is released, it automatically returns to the RUN position.

Snowmobiles equipped with electric start and/or IDD are equipped with a battery. If the key remains in the RUN position after using the engine stop switch to stop the engine, the IDD remains active. The IDD screen will turn off after several minutes of inactivity, but the IDD will continue to draw a small amount of current from the battery until the key is turned off. This feature is useful for accessing the IDD without starting the engine, but turn the key off when the IDD is not in use.

The IDD is not dependent on the battery while the engine is running, but the battery supplies a constant power source when the engine is turned off or when the engine is transitioning between forward and reverse operation. If the battery is not installed, the IDD reboots when the engine is started and when electronic reverse (PERC) is used.

OPERATION

Starting the Engine

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

1. Turn the key to the ON position.

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

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

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

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

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

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

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

snap back into the housing. Damage may result.

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

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.

OPERATION

Starting 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 clear the engine.

5. Release the throttle.

6. Restart the engine using the normal starting procedure.

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.

Oil Recommendations

First Tank of Fuel: POLARIS VES 2-Cycle Oil After Break-in: POLARIS VES 2-Cycle Oil Extreme Arctic Conditions, sustained

temperature is at or below -40° F (-40° C)

See page 124 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.

VES RACE 2-Cycle Oil

Fuel VES 2-Cycle Oil Ratio

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

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 closefitting machined parts, allowing them to break in slowly without damage.

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

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 75.

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

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.

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

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

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.

OPERATION

Track Warm-Up

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

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

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

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

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

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

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

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

temperatures.

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

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

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.

OPERATION

WARNING

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 turn off the engine before refueling.

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

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

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

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

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

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

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 124 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.

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

Always protect painted surfaces when handling fuel.

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 70 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

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

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.

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.

OPERATION

WARNING

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 or transmission if shifting is attempted when the engine is operating above idle speed.

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

• Look behind the 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 transmission is in reverse. Never engage the starter when the engine is running.

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

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

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

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

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

restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

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

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

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

forward.

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 76 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

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 down to maintain control of the snowmobile.

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

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

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

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 hang tag. 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 hang tag, 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.

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 137.

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.

MAINTENANCE

Periodic Maintenance Interval Table

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

Item See

Clutch Alignment Offset (without belt)

Drive Belt Condition 103 II II Clutches 103 CCC Belt Tension -- IIII Clutch Sheaves 103 IIII

Engine Mounts -- II II Recoil Rope -- IIII Cylinder Head Bolts -- III Cylinder Base Nuts -- III Ignition Timing BTDC -- III VES System -- CCC I Coolant Level 94 IIII Coolant Change 95 R - Every 5 years Coolant Hose -- II II Coolant Circulation -- III Coolant Leaks -- IIII Spark Plugs 93 IIRI Exhaust Pipe 97 II Exhaust Retaining

Springs

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

Page

150 mi.

(240 km)

103 III

ENGINE/COOLING

97 IIII

CLUTCH

500 mi.

(800 km)

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Hose Routing -- II II Hose Condition -- II II Fluid Leaks -- IIII Brake Pads 98 IIII Brake Disc -- IIII Parking Brakes 64 IIII Brake System 63, 98 I Brake Fluid 99 I

Idle RPM -- III Throttle Lever 77 II I II Oil Pump Lever

(synchronize) Throttle Position Sensor -- III Fuel / Vent Hoses 91 III II Fuel Filter 91 EVERY 2000 (3200) or EVERY 2 YEARS Oil Filter 90 RR Oil Lines 90 III Air Box -- II I I I

Auxiliary Shut-Off Switch

Throttle Safety Switch 76 II I I I Ignition Switch -- II I II Taillight 66 III II Brakelight 66 III II Headlight 66 III II

Page

150 mi.

(240 km)

FUEL MANAGEMENT

-- III

ELECTRICAL

66 II I II

BRAKES

500 mi.

(800 km)

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Ski Toe Alignment -- III Suspension Mounting

Bolts Bolt Torques See your dealer every 1000 mi. (1600 km) for inspection Rear Suspension

Fasteners Steering Fasteners -- II I IC Cooling Fins and

Shroud Skags (Wear Bars) 113 III I I Ski Saddle/Spindle Bolts -- II I II Drive Chain Tension 97 III II Hood and Side Panel

Fasteners Rear Wheel Idler Bolts 109 III II Idler Bolt Jam Nut 109 III I I Camber Alignment -- III Handlebar Centering -- I Tether Switch and Strap 66 III II Track Alignment 110 II I I I Track Tension 108 III II Front Limiter Strap -- II I I I Rail Slide Condition 113 I Chaincase Oil 89 IRI RI

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

Page

150 mi.

(240 km)

-- III I I

-- IIII

87 II I II

(800 km)

CHASSIS

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Strap

1/4-Turn Fasteners

Hood/Side Panel

T o 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.

MAINTENANCE

Lubrication

Rear Suspension

Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 84 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

Lack of lubrication will adversely affect your ride and the life of the suspension. Lubricate where indicated in the illustration below. For more information about suspension lubrication and adjustments, see your POLARIS dealer.

MAINTENANCE

Lubrication

Chaincase Oil

Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning on page 83. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube. See page 124 for the part numbers of POLARIS products.

Oil Level

The fill plug is located on the right side of the snowmobile under the toe bar.

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).

Fill Plug

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).

MAINTENANCE

Lubrication

Oil Lines

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

Oil Filter

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

TIP:The direction of the arrows indicates

the direction of flow through the filter.

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

84. 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.

MAINTENANCE

Spark Plugs

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 83. 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 118.

MAINTENANCE

Spark Plugs

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

specification.

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.

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

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

Wet Fouled 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.

MAINTENANCE

Cooling System

Coolant

POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 124 for the part numbers of POLARIS products.

Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix.

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

MAINTENANCE

“Full Cold” Mark

Cooling System

Coolant Level

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

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added. 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.

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

MAINTENANCE

Cooling System

Bleeding the Cooling System

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

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

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

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

1. Position the vehicle so that the top of the tunnel is level. Elevate the

2. Make sure the engine is cold before continuing.

3. Remove the right side panel.

4. Fill the coolant bottle with properly mixed coolant to the maximum

5. Remove the bleed screw from the water outlet manifold and/or the

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

7. Reinstall the side panel. Always ensure that the hood and side

8. Start the engine and run at a fast idle for two to three minutes.

9. Stop the engine and check the coolant bottle level. Add coolant as

10. Carefully and briefly touch the top of the tunnel cooler under the

11. Remove the side panel. Reinstall the pressure cap. Reinstall the side

12. Carefully lower the front end of the snowmobile.

engine damage may result.

front of the vehicle slightly if necessary.

mark. Do not install the pressure cap at this time.

thermostat housing. Allow the coolant to bleed through the system until it runs out the bleed holes. Reinstall the bleed screw into the manifold.

panels are securely in place before starting the engine.

Loosen the bleed screw occasionally to purge any trapped air.

needed. Reinstall the side panel.

seat. If the system is bled properly, the cooler will be warm to the touch. If not, repeat step 8. Lift the front of the snowmobile slightly to assist in the bleeding.

panel.

MAINTENANCE

Jam

Nut

Adjuster

Bolt

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 87.

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.

Drive Chain Tension

Check drive chain tension weekly and before each long trip.

1. Remove the side panels.

2. Rotate the driven clutch

counter-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.

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 Disc

2. Brake Caliper

3. Anti-rattle springs (come

with brake pad kit)

4. Brake Pad Material (Replace

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

Excessive Lever Travel

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

Polaris 600 Switchback Assault 144 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual