Polaris 800 INDY XC 129 2019 Owner's Manual

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2019

Owner’s MAnual

800 INDY XC 129 600 INDY XC 129

600 INDY SP

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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

Operating, servicing, and maintaining a passenger vehicle or off-road

vehicle can expose you to chemicals including engine exhaust, carbon

monoxide, phthalates, and lead, which are known to the State of California

to cause cancer and birth defects or other reproductive harm. To minimize

exposure, avoid breathing exhaust, do not idle the engine expect as

necessary, service your vehicle in a well-ventilated area and wear gloves

or wash your hands frequently when servicing your vehicle.

For more information go to www.P65Warnings.ca.gov/passenger-vehicle.

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

code with your smartphone.

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2019 Owner’s Manual

800 INDY XC 129 ES

600 INDY SP 129 ES 600 INDY XC 129 SC Select 800 INDY XC 129 SC Select

600 INDY XC 129 ES INTL SC

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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.

2019 Owner's Manual 9928880

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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. 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.

• Snowmobiles

• SPORTSMAN® All-terrain vehicles

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• BRUTUS® work vehicles

• SLINGSHOT® three wheel motorcycles

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 can be performed by a factory certified Master Service Dealer® (MSD) technician.

• RZR® sport vehicles

• GEM® vehicles

• INDIAN® motorcycles

• POLARIS POWER® generators

• POLARIS DEFENSE® combat vehicles

• Timbersled® Snow Bikes

Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Your POLARIS dealership can perform all of your service needs during, and after, the warranty period.

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SAFETY SYMBOLS AND SIGNAL WORDS

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.

DANGER

DANGER indicates a hazardous situation which, if not avoided, WILL result in

death or serious injury.

WARNING

SAFETY ALERT WARNING indicates a hazardous situation which, if not

avoided, COULD result in serious injury.

CAUTION

SAFETY ALERT CAUTION indicates a hazardous situation which, if not

avoided, COULD result in minor to moderate injury.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle

damage or property damage.

IMPORTANT

IMPORTANT provides key reminders during disassembly, assembly, and

inspection of components.

NOTICE

NOTICE provides key information by clarifying instructions.

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.

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TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . 7

Safety . . . . . . . . . . . . . . . . . . . . . . 11

Features . . . . . . . . . . . . . . . . . . . . . 31

Gauge . . . . . . . . . . . . . . . . . . . . . 41

The Perfect Fit . . . . . . . . . . . . . . . . . . 65

Pre-Ride Inspections . . . . . . . . . . . . . . . 81

Operation . . . . . . . . . . . . . . . . . . . . 87

Maintenance . . . . . . . . . . . . . . . . . . 97

Specifications . . . . . . . . . . . . . . . . . . 139

Troubleshooting . . . . . . . . . . . . . . . . . 149

Warranty . . . . . . . . . . . . . . . . . . . . 159

Maintenance Log . . . . . . . . . . . . . . . . 169

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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 at specific mileage intervals. This service can be performed by your authorized POLARIS dealer.

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.

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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 nonsnowmobilers, 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.

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INTRODUCTION

VEHICLE IDENTIFICATION NUMBERS

Record your snowmobile's identification numbers and key number in the spaces provided.

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.

Certification Label

Tunnel VIN

Emission Certification Label

VEHICLE MODEL NUMBER:

TUNNEL VIN (RIGHT SIDE OF TUNNEL):

ENGINE SERIAL NUMBER (ON RECOIL HOUSING):

KEY NUMBER:

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INTRODUCTION

ENGINE SERIAL NUMBER

The engine serial numberqis located on the identification label on the engine recoil cover.

KEY IDENTIFICATION

The ignition keys are etched with an identification number. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank using the same identification number with one of your existing keys, so if both keys are lost, the ignition switch assembly must be replaced.

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SAFETY

OPERATOR SAFETY

Follow the recommended maintenance program beginning on page 98 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected at specific mileage intervals. Your dealer can perform this service.

WARNING

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

reduce your alertness and slow your reaction time.

Snowmobiles are capable of traveling at high speeds. Use extra caution to

ensure operator safety. Make sure your snowmobile is in excellent operating

condition at all times. Always check major and vital safety components before

every ride.

All POLARIS snowmobiles are designed and tested to provide safe operation

when used as directed. Failure of critical machine components may result from

operation with any modifications, especially those that increase speed or

power. DO NOT MODIFY YOUR MACHINE. The snowmobile may become

aerodynamically unstable at speeds higher than those for which it is designed.

Loss of control may occur at higher speeds. Modifications may also create a

safety hazard and lead to bodily injury.

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

of the snowmobile.

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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.

RIDER CAPACITY

Some POLARIS snowmobiles are designed for a single rider only, while some are designed for up to two riders. A safety label on the vehicle indicates whether the vehicle is designed for a single rider or for two riders.

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SAFETY

RIDING APPAREL

HELMET

Wearing a helmet can prevent a severe head injury. Whenever riding this 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.

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SAFETY

CLOTHING

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.

Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See page 26.

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

• Extra Set of Spark Plugs

• Tow Rope

• Extra Oil

• Fuel Deicer

• Winter Survival Kit

• Trail Map

• First Aid Kit

• Tool Kit

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SAFETY

EXCESSIVE SPEED

WARNING

High speed driving, especially at night, could result in serious injury or death.

Always reduce speed when driving at night or in inclement weather.

Always 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.

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.

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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.

MOUNTAINOUS TERRAIN RIDING

Mountainous terrain operation, even for experienced riders, can present conditions and situations that could result in serious injury or death. Please review all of the information about riding in mountainous terrain on the following pages of this manual.

WARNING

An avalanche can occur at any time, in any conditions and on any slope.

The avalanche information provided in this manual should be considered basic information and is not intended to replace your participation in an avalanche safety training course. After reviewing the avalanche information in this manual, be sure to participate in an avalanche safety training course before riding in mountainous terrain. The training course will provide more information as well as the opportunity to practice riding and using proper search and recovery techniques.

For more information, education, training courses, and links to international resources, visit www.avalanche. org or scan the QR code with your smartphone or other device.

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SAFETY

GET THE SAFETY GEAR

In addition to carrying a spare belt, spark plugs and tools on each snowmobile, each person in your riding group should wear the recommended snowmobile riding apparel and carry (on their person) the following survival items when riding in mountainous terrain:

• A digital avalanche beacon with new “fresh” alkaline batteries

• An avalanche probe

• A compact shovel and hand saw

• A backpack (preferably an avalanche air bag backpack)

• Emergency provisions, including the following items:

– Small first aid kit – Extra pair of gloves – Extra dry socks – Tow rope, map, compass/GPS – Lighter or waterproof matches – Signal mirror and whistle – Bottled water – High calorie snack food – Compact emergency blanket

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SAFETY

GET TO KNOW YOUR SAFETY GEAR

Following the safety gear and apparel recommendations will increase your chances of survival if you encounter an avalanche or become stranded in the backcountry, but even experienced and properly-equipped snowmobilers, hikers and skiers perish in avalanches or succumb to hypothermia. Using a beacon or probe for the first time during an avalanche recovery operation, or not knowing how to deploy your avalanche air bag backpack during a slide, should be considered UNACCEPTABLE to you and all members of your riding group. It’s critical that you and all members of your riding group know how to use the safety gear.

While you may know how to use your gear, you may have to rely on your riding group to find you in an avalanche. Make sure they know how to use their gear.

• Dress in layers. Multiple layers of clothing provide the best barrier to cold and wind. Layers can be removed, but if you start out without enough layers, they cannot be added later. Avoid cotton materials, which will freeze if they get wet.

• Wear highly visible gear.

• Try on all gear and equipment to make sure it fits and doesn’t interfere with your riding capabilities. Place all survival aids in your backpack and wear the backpack at all times. Non-essential items can be stored on the snowmobile in an accessory bag.

• Read and follow the manufacturer’s user and maintenance instructions for all gear. If you have questions about how your gear works, contact the manufacturer for more information.

• Practice using your beacons, shovels and probes with your riding group in real-world conditions wearing all of your gear. Have someone hide an active “transmitting” beacon by throwing it (not walking it) into a snowbank and timing your group’s search for it.

• Test deploying your gear. If you own an avalanche air bag backpack, check with the manufacturer’s test deployment guidelines and bottle weight replacement specifications. Most air bag backpack manufacturers recommend testing the pack once a year so you know it works and feel comfortable with the bag and deployment time.

• Make sure your probe and shovel are in good condition and that you know how to assemble them.

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SAFETY

GET THE PICTURE

Slopes steeper than 30º are more prone to avalanches, but any slope should be considered avalanche terrain, even small slopes with trees. Low-angle slopes are also avalanche terrain if they have steeper slopes above them.

NOTE

The 30º slope graphic is for illustration purposes only. The risk of an avalanche

is always present in mountainous terrain, regardless of slope angle.

Always look for the following warning signs of unstable snow. If you see or hear any of these signs, riding on or below any slope is dangerous and should be avoided:

• Recent avalanches

• A “whumpfing” sound under a snowpack

• Cracks across the top of a snowpack

• A recent heavy snowfall

• Blowing snow

• Rain

• Rapid warming

GET OUT OF HARM’S WAY

• Before riding, always tell a responsible person (i.e. at the lodge or gas station) where your group is going.

• Never ride alone. Always ride in a small, manageable group. Riding in a large group makes it more difficult to track riders or find missing members.

• Go “one at a time”. Only one snowmobile at a time should cross, ascend or highmark a slope. Other riders should watch from a safe location until the previous rider exits the slope.

• Never park at the base of a slope or at the bottom of a gully or valley. When parking to take a break or watch other riders, park at the sides of the slope with the front of your snowmobile pointed away from the slope.

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SAFETY

GET THE FORECAST

Make a riding plan based on the current avalanche and weather forecast. It is important to remember that overnight weather conditions may have created unsafe riding terrain that was considered safe the day before. Visit www.avalanche.org or scan the QR code. Follow the page links to locate current avalanche reports and conditions for your area of operation.

GET AVALANCHE SAFETY TRAINING

POLARIS recommends you and all members of your riding group participate in an avalanche safety course. Visit www.avalanche.org/education or scan the QR code for education and training resources.

AVALANCHE AWARENESS

Avalanches are a matter of timing. A steep slope can be safe one day, but unsafe the next day due to changing weather and wind conditions.

• Always review the user instructions provided with your safety equipment and follow the recommendations for maintenance, testing and use. Always test your safety equipment to ensure it works properly before riding in mountainous terrain.

• Always store your survival gear in your backpack and wear the backpack. Do not store your survival gear on the snowmobile.

• Always research current avalanche conditions in your area of operation before riding. Check with local law enforcement, resort or lodging personnel, gas station attendants and other riders to learn about current conditions and any advisories in the area.

• Read and understand the avalanche danger scale. Pay attention to any danger level warnings issued for your area of operation.

• Always remain alert while riding in mountainous terrain. Be aware of snowpack conditions above you as you ride. Avalanches can occur at any time regardless of current condition reports.

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SAFETY

North American Public Avalanche Danger Scale

Avalanche danger is determined by the likelihood, size and distribution of avalanches.

DANGER LEVEL TRAVEL ADVICE LIKELIHOOD

AVALANCHES

Extreme

High

Considerable

Avoid all avalanche

terrain.

Very dangerous

avalanche

conditions. Travel

in avalanche terrain

not recommended.

Dangerous

avalanche

conditions. Careful

snowpack

evaluation,

cautious route-

finding and

conservative

decision-making

essential.

human-triggered

likely; human-

avalanches very

human-triggered

Natural and

avalanches

certain.

Natural

avalanches

triggered

likely.

Natural

avalanches

possible;

avalanches

likely.

AVALANCHE

SIZE AND

DISTRIBUTION

Large to very

large avalanches

in many areas.

Large

avalanches in

many areas; or

very large

avalanches in

specific areas.

Small

avalanches in

many areas; or large avalanches in specific areas;

or very large

avalanches in

isolated areas.

Heightened

avalanche

conditions on

Moderate

Low

Safe backcountry travel requires training and experience. You control your own risk by

choosing where, when and how you travel.

specific terrain

features. Evaluate

snow and terrain carefully; identify

features of

concern.

Generally safe

avalanche conditions. Watch for unstable snow on isolated terrain

features.

Natural

avalanches

unlikely; human-

triggered

avalanches

possible.

Natural and

human-triggered

avalanches

unlikely.

Small

avalanches in specific areas; or large avalanches in isolated areas.

Small

avalanches in isolated areas or

extreme terrain.

Page 24

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 hard-packed

snow reduces steering and braking control, which may result in loss of control

and serious injury or death. Slow down and use extra caution when operating

on slippery surfaces.

INADEQUATE SNOW CONDITIONS

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

NOTICE

Driving in too little snow will result in excessive wear and damage to the slide

rail, track and/or engine.

WARNING

Inadequate cooling and lubrication will lead to overheating of the slide rail and

track, causing premature wear, damage and failure, which can result in serious

injury. Reduce speeds and frequently drive into fresh snow to allow adequate

cooling and polishing of the slide rail and track surfaces. Avoid operating for

prolonged periods on ice, hard-packed surfaces or roads.

OPERATING IN DEEP SNOW

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

Page 25

SAFETY

DRIVING DOWNHILL

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

WARNING

When driving on long downhill stretches, pump the brakes. Riding the brakes

may cause the brake system to overheat, which may result in brake failure.

Excessive or repetitive use of the brakes for high speed stops will also cause

an overheated brake system. This condition may lead to a sudden loss of

brakes and/or fire and may result in serious injury or death.

DRIVING IN HILLY TERRAIN

WARNING

Climbing a hill or crossing the face of a slope may result in loss of balance and

snowmobile rollover, causing serious injury or death. Use caution and good

judgement when driving in hilly terrain.

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

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

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

Page 26

SAFETY

DRIVE BELT

Do not operate the engine with the drive belt removed.

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

WARNING

Operation of the engine with the belt removed may result in injury or damage to

the engine.

INTAKE SILENCER

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

NOTICE

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

CLUTCHES

Do not attempt to service the clutches.

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

COLD WEATHER DRIVE-AWAY

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

MANEUVERABILITY

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

Page 27

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.

Page 28

SAFETY

WINDCHILL/TEMPERATURE CHARTS

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

WINDCHILL CHART (°F)

Wind

Speed

in MPH

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

5 36 31 25 19 13 7 1 -5 -11 -16 -22 -28 -34 -40 -46 -52

10 34 27 21 15 9 3 -4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72 15 32 25 19 13 6 0 -7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77 20 30 24 17 11 4 -2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81 25 29 23 16 9 3 -4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84 30 28 22 15 8 1 -5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87 35 28 21 14 7 0 -7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89 40 27 20 13 6 -1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91 45 26 19 12 5 -2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93 50 26 19 12 4 -3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95 55 25 18 11 4 -3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97 60 25 17 10 3 -4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98

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

Frostbite in >> 30 min. 10 min. 5 min.

Actual Thermometer Reading (°F)

Equivalent Temperature (°F)

-57 -63

WINDCHILL CHART (°C)

Wind

Speed

in Km/h

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

8 3 0 -4 -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50

16 2 -2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 24 1 -3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 32 0 -4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67 40 -1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69 48 -1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70 56 -2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72 64 -2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73 72 -2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74 80 -3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75 88 -3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76 96 -3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

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

Frostbite in >> 30 min. 10 min. 5 min.

Actual Thermometer Reading (°C)

Equivalent Temperature (°C)

-53 -57

Page 29

SAFETY

SAFETY LABELS AND LOCATIONS

Warning labels are placed on the snowmobile for your protection. Read and follow the instructions of the labels and 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.

NO PASSENGER WARNING (ONE RIDER MODELS)

The No Passenger Warning/Fuel Recommendation labelqis located below the steering post.

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.

REVERSE WARNING

The Reverse Warning label

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.

is located on either side of the operator seat.

• Push button again to return to forward.

Page 30

SAFETY

TUNNEL WARNING

The Tunnel Warning label is located on the rear of the tunnel.

WARNING

Hot Surface Do Not Touch Burn may result. Entire top of tunnel may be hot. Install

only accessories specifically approved for this model by Polaris.

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.

MAX. 25 lbs.

CLUTCH WARNING/BELT REMOVAL

The clutch warning labeleis 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. Your dealer

can perform this service.

BELT REMOVAL - ALL UNITS

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

2. Install L-wrench from fender 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 fender.

SEE OWNER’S MANUAL FOR SHEAVE WIDTH ADJUSTMENT PROCEDURE.

Page 31

SAFETY

OPERATION WARNING

The operation warning label is 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.

• 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 operation. Make sure hood and side panels are latched. Be seated and in position to control the vehicle.

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

Page 32

Page 33

FEATURES

COMPONENT LOCATIONS

NOTE

The figures below are for reference only. Your model may differ slightly.

Skis

Nosepan

Front Bumper

Hood

Headlight

Windshield (accessory)fLower Control Arm

Handlebar

Operator Seat

Taillight

Rear Bumper

Snow Flap

Upper Control Arm

Spindle

Independent Front

Suspension

Side Panel

Torsion Spring

Rear Track Shock

Front Track Shock

Rail

Page 34

FEATURES

CONTROLS

Brake Lever

Parking Brake Lock

Ignition Switch

Instrument Cluster

Engine Stop Switch

Throttle Control

Recoil Starter Handle

Handlebar Grip Warmer Switch

Thumb Warmer Switch

Electronic Reverse Button

Headlight Dimmer Switch

MODE/SET Switch

Page 35

FEATURES

IGNITION SWITCH

OFF Vehicle / PIDD power off RUN Vehicle / PIDD power on START Activates starter motor (if

equipped)

The ignition switch has three positions: OFF, RUN, and START.

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.

NOTE

If the key remains in the RUN position after using the engine stop switch to

stop the engine, the PIDD (POLARIS Interactive Digital Display) remains

active. The PIDD screen will turn off after several minutes of inactivity, but if a

battery is installed, the PIDD 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 PIDD without starting the engine, but turn the key off when the PIDD is not

in use.

The PIDD is not dependent on a battery while the engine is running, but a

battery (if installed) supplies a constant power source when the engine is

turned off or when the engine is transitioning between forward and reverse

operation. If a battery is not installed, the PIDD reboots when the engine is

started and when electronic reverse (PERC) is used.

Page 36

FEATURES

12-VOLT DC POWER RECEPTACLE

If equipped, the 12-volt DC power receptacle is located on the hood next to the instrument cluster. The 12-volt power receptacle is protected by a 2 amp mini blade fuse located in the protective bag above the clutch cover. Use of the 12-volt DC power receptacle is recommended for connecting powersensitive devices such as GPS units and cell phones.

NOTE

The 12-volt DC power receptacle and the jumper harness required to connect

the receptacle to the hood wiring harness can be purchased from your

POLARIS dealer.

12-VOLT RCA POWER SOURCES

Some rider accessories require the use of an RCA power adapter. If your model is not equipped with an RCA power plug on the handlebar cover, an accessory 12-volt RCA adapter or RCA power plug can be purchased from your POLARIS dealer.

12-VOLT RCA ADAPTER

The RCA adapter can be used if your model is equipped with the 12-volt DC power receptacle. Plug the adapter into the receptacle to convert it to a 12-volt RCA power outlet.

12-VOLT RCA POWER PLUG

The RCA power plug (with cover) mounts to the handlebar cover and is plugged into the main vehicle wire harness. Installation instructions are provided with the accessory. This power point is powered by the load shed relay and is not fuse protected. POLARIS recommends using this power point for electric helmet shields.

Page 37

ADJUSTABLE HEADLIGHT

NOTE

The image below is for reference only. Your model may differ slightly.

FEATURES

The headlight can be adjusted for vertical aim using the following procedure.

1. In a well-ventilated area, position the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wallq.

2. Place the rider or the approximate weight of the rider on the seat or tunnel floorboards.

3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

4. Start the engine. Move the headlight switch to high beam.

5. Observe the headlight aim on the wall. The most intense part of the headlight beam should be two inches (5 cm)

6. If adjustment is necessary, access the headlight adjuster knob through the left side panel. Turn the adjuster knob clockwise to lower the beam. Turn the adjuster counter-clockwise to raise the beam.

below the mark on the wall.

Page 38

FEATURES

TOOLS

The belt removal L-wrench tool, spare belt, spark plug, and spark plug tool container are located behind the left engine compartment panel.

NOTE

Spare belt and spark plugs are not provided with the snowmobile.

L-WRENCH

When properly engaged in the bracket, the L-wrench secures the fender to the console. To retrieve the L-wrench, rotate it counter-clockwise and slide it upward from the bracket. Return the Lwrench to the bracket and rotate it clockwise when it’s not in use.

SPARK PLUG WRENCH

The spark plug wrench secures the spare belt/spark plug tool container to the front bumper. Remove the container to add or access a spare spark plug or belt.

REPLACEMENT DRIVE BELT

To insert a replacement drive belt into the spare drive belt container, do the following:

1. Rotate the spark plug wrench counter-clockwise to release it from the bracket.

2. Pull the wrench upward to remove it.

3. Tilt the container until the bracket detaches from the bumper tube.

4. Pull the container out of the compartment.

5. When placing a drive belt into the container, fold the belt as shown. Verify that the belt loop at the rear of the container is positioned slightly higher than the front loop.

6. Slide the container into the engine compartment at an angle.

7. Position the container bracket onto the bumper tube and rotate it downward.

8. Reinstall the spark plug wrench into the bracket and through the hole in the bumper tube.

9. Rotate the spark plug wrench clockwise until it locks into place.

Page 39

FEATURES

DETONATION ELIMINATION TECHNOLOGY (DET)

When DET senses and takes action to reduce detonation, the driver may notice a drop in engine RPM and/or reduced performance. The ECU will illuminate the check engine LED and display “DETONATION” on the LCD screen whenever the DET system is active.

If the ECU determines the detonation cannot be controlled by normal means, and further operation may cause engine damage, the check engine LED will flash, the instrument clusters will display “DETONATION” and the ECU will either limit the maximum engine speed or turn off the engine.

If the ECU limits RPM, the limit will remain active until the driver stops and restarts the engine.

DETONATION PROTECTION MODES

Check Engine LED/Gauge Display Protection Mode

600 Models

LED illuminated / “DETONATION” displayed Slight drop in engine RPM/power

LED flashing / “DETONATION” displayed Engine shut-off

800 HO Models

LED illuminated / “DETONATION” displayed Slight drop in engine RPM/power

LED flashing / “DETONATION” displayed Exhaust valves close to reduce engine RPM/

power. Restart engine to reset.

The most likely causes of severe detonation are outlined in the troubleshooting table on page 154.

NOTE

The PIDD alert indicates which cylinder is experiencing detonation

OIL PUMP FAILURE PROTECTION (IF EQUIPPED)

If the ECU determines there is a problem with the electronic oil pump control circuit, the engine management system will limit engine speed to approximately 4000 RPM and illuminate the check engine indicator light on the instrument cluster or PIDD.

Page 40

FEATURES

ENGINE OVERHEAT INDICATORS

OVER-TEMPERATURE INDICATOR (STANDARD CLUSTER)

The over-temperature indicator on the standard instrument cluster will illuminate when the engine is overheating. Take action to cool the engine. See page 39. The indicator will flash when engine temperature reaches critical levels. Stop the engine

immediately.

OVERHEAT WARNING (PIDD)

The engine temperature scale located on the right side of the PIDD screen changes to RED and the check engine temperature indicator on the top left of the screen illuminates when the engine is overheating. Take action to cool the engine. See page 39. The indicator will flash when engine temperature reaches critical levels.

Stop the engine immediately.

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

600/800 HO MODELS ENGINE TEMPERATURE PROTECTION MODES

Hot Lamp Threshold*

ON Lamp illuminates: Idle = 201° F (94° C), WOT = 185° F (85°

located

FLASHING Lamp Flashes, Engine Turns Off: Idle = 215.6° F (102° C),

WOT = 201° F (94° C)

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

Page 41

FEATURES

FLASHING INDICATOR

Flashing indicators indicate continued operation could result in serious engine damage. The engine management 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 poor

cooling conditions, your dealer can perform this service.

ENGINE-COOLING ACTIONS

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

• Drive in loose snow.

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

• Stop the engine and allow it to cool down.

• Add coolant if the level is low. Do not add coolant while the engine is hot. Wait

for the engine to cool before adding coolant.

NOTICE

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

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

EXTENDED IDLE ENGINE SHUTOFF

This engine feature causes the ECU to shut down the engine when engine temperature reaches 120° F (50° C) and there is no throttle lever input for five minutes.

NOTE

If equipped with an PIDD, the gauge will remain on because the key is in the

ON position.

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

Page 42

Page 43

GAUGE

STANDARD INSTRUMENT CLUSTER

GAUGE

Check Engine

Engine Hot

Low Oil

Low Battery Voltage

Playback

Low Fuel

High Beam

Parking Brake

Reverse

Security

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.

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 Hand Control.

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GAUGE

INDICATOR LAMPS

INDICATOR CONDITION

This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning appears. Serious engine damage could result. Your dealer can assist.

The over-temperature indicator will illuminate when the engine is overheating. Take action to cool the engine. The indicator will flash when engine temperature reaches critical levels. Stop the engine

immediately.

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.

The low battery voltage indicator illuminates when the battery voltage is low.

The playback indicator illuminates when the gauge is in playback mode.

The low fuel indicator illuminates when fuel is low.

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

The parking brake Indicator illuminates when the parking brake is engaged. It will also illuminate when the service brake is in use.

The reverse indicator flashes when the transmission is in reverse.

The security indicator illuminates when the security system is activated.

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GAUGE

RIDER INFORMATION CENTER

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

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.

Speed Display - The speed display area displays either vehicle speed or

engine speed.

Fuel Gauge - Not available on all models. The segments of the fuel gauge

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

NOTE

The low fuel indicator and fuel level gauge on the Standard Instrument Cluster

are not supported on models with a fuel level gauge on the fuel cap.

Odometer/Engine Hour Display - This area displays the odometer, Trip A,

Trip B and engine hours.

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GAUGE

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 release the center

button.

INFORMATION DISPLAY AREA

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

ODOMETER/ENGINE HOUR DISPLAY AREA

This area displays the odometer, Trip 1 meter, Trip 2 meter, CLOCK, 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 CLOCK displays the time, and the engine hour meter displays the total hours the engine has been in operation since manufacture.

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

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

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GAUGE

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.

TO RECORD

1. Press and hold the center Options Menu.

2. Press and release the MODE button until PLAYBACK appears in the information display area.

3. Press and release the SET button.

RECORD will appear in the information display area.

button on the instrument cluster to enter the

4. To begin recording, Press and release the SET button.

The playback indicator will flash while recording is in progress. Recording is complete when the light stops flashing.

NOTE

To stop recording at any time during the recording process, press and release

the SET button.

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GAUGE

TO PLAYBACK

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

2. Press and hold the center Options Menu.

3. Press and release the MODE button until PLAYBACK appears in the information display area.

4. Press and release the SET button twice.

PLAY will appear in the information display area.

button on the instrument cluster to enter the

5. Press and release the SET button to play the recorded data.

Once playback has concluded, REPLAY will appear in the information display area.

6. Press and release the SET button to REPLAY recorded data.

7. Press and release the MODE button to end playback and return to the Options Menu.

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GAUGE

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 hold the center Options Menu.

2. Press and release the MODE button until engine temperature appears in the information display area.

3. Press and release the SET button or SET switch to change units.

Change Method 2

1. Press and release the SET button or SET switch until the odometer appears in the information display area.

button on the instrument cluster to enter the

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

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GAUGE

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.

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

NOTE

To lock the system for the first time, use code 000.

1. Press and hold the center Options Menu.

2. Press and release the MODE button until SECURITY OFF appears in the information display area.

button on the instrument cluster to enter the

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GAUGE

3. Press and release the SET button.

ENTER CODE will appear in the information display area.

4. Press and release the SET button to increase the 1st digit.

5. Press and hold the SET button to accept the 1st digit and advance to the 2nd digit.

6. Press and release the SET button to increase the 2nd digit.

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GAUGE

7. Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit.

8. Press and hold the SET button to accept the 3rd digit and submit code.

If code is correct, SECURITY ON will appear in the information display area. The system is now locked. Proceed immediately to Task 3.

If code is incorrect, BAD CODE will appear in the information display area. Return to step 3 to re-enter code.

Page 53

TASK 3: Unlock the System

NOTE

To unlock the system for the first time, use code 000.

1. While the engine is running, Press and release the SET button.

ENTER CO will appear in the information display area.

GAUGE

2. Press and release the SET button to increase the 1st digit.

3. Press and hold the SET button to accept the 1st digit and advance to the 2nd digit.

4. Press and release the SET button to increase the 2nd digit.

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GAUGE

5. Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit.

6. Press and release the SET button to increase the 3rd digit.

7. Press and hold the SET button to accept the 3rd digit and submit code.

If code is correct, SECURITY OFF will appear in the information display area

NOTE

The system is now unlocked.

If code is incorrect, BAD CODE will appear in the information display area. Return to step 1 to re-enter code.

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

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GAUGE

TASK 4: Enter Your New Security Code

1. Immediately after locking and unlocking the system, and while SECURE OFF is displayed, simultaneously press and hold the MODE and SET buttons.

SET NEW CODE will appear on the information display area.

2. Press and release the SET button to increase the 1st digit.

3. Press and hold the SET button to accept the 1st digit and advance to the 2nd digit.

4. Press and release the SET button to increase the 2nd digit.

5. Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit.

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GAUGE

6. Press and release the SET button to increase the 3rd digit.

7. Press and hold the SET button to accept the 3rd digit.

CODE SET will appear in the information display area, and then the new code will blink three times in the information display area

NOTE

Your new code is now set. The system is NOT locked.

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

Record your new personal security code here: __________________

TIP

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

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

your own choosing.

LOCKING SYSTEM WITH PERSONAL SECURITY CODE

1. Start the engine.

2. Press and hold the center Options Menu.

button on the instrument cluster to enter the

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GAUGE

3. Press and release the MODE button until SECURITY OFF appears in the information display area.

4. Press and release the SET button.

ENTER CODE will appear in the information display area.

5. Press and release the SET button to increase the 1st digit.

6. Press and hold the SET button to accept the 1st digit and advance to the 2nd digit.

7. Press and release the SET button to increase the 2nd digit.

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GAUGE

8. Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit.

9. Press and hold the SET button to accept the 3rd digit and submit code.

If code is correct, SECURITY ON will appear in the information display area. The system is now locked. Proceed immediately to Task 3.

If code is incorrect, BAD CODE will appear in the information display area. Return to step 3 to re-enter code.

Page 59

UNLOCKING SYSTEM WITH PERSONAL SECURITY CODE

1. While the engine is running, Press and release the SET button.

ENTER CODE will appear in the information display area.

2. Press and release the SET button to increase the 1st digit.

GAUGE

3. Press and hold the SET button to accept the 1st digit and advance to the 2nd digit.

4. Press and release the SET button to increase the 2nd digit.

5. Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit.

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GAUGE

6. Press and release the SET button to increase the 3rd digit.

7. Press and hold the SET button to accept the 3rd digit and submit code.

If code is correct, SECURITY OFF will appear in the information display area

NOTE

The system is now unlocked.

If code is incorrect, BAD CODE will appear in the information display area. Return to step 1 to re-enter code.

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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. 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

1. Start engine

2. Press and hold the

center

3. Press and release the SET button until SECURITY appears in information display area.

4. Press and release SET button.

Press and release the SET button

Press and hold the SET button

button

Displays ENTER CODE (to lock the system)

Advances a digit on the ENTER CODE screen

Accepts a digit and displays the next digit position (if any remain) on the ENTER CODE screen

While SECURITY OFF is shown on the information display area, simultaneously Press and hold the MODE and SET button.

Allows user to change security code.

Page 62

GAUGE

DIAGNOSTIC DISPLAY MODE

The diagnostic display mode is for informational purposes only. Your POLARIS dealer can perform 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 can help retrieve inactive codes.

Use the following procedure to view active codes.

1. Do not stop the engine.

2. Press and hold the center Options Menu.

3. Press and release the MODE button until DIAGCODE appears in the information display area. The Diagnostic display mode will appear in the Options Menu if there is an active trouble code.

button on the instrument cluster to enter the

TIP

When the diagnostic mode is displayed, the check engine warning indicator will

begin to flash.

4. 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.

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

6. See Diagnostic Trouble Codes for code definitions and failure descriptions.

Page 63

GAUGE

POLARIS INTERACTIVE DIGITAL DISPLAY (PIDD)

The POLARIS Interactive Digital Display (PIDD) provides the rider with:

• Speedometer

• Tachometer

• Odometer

• 2 Trip Meters

• Fuel Level Indicator

• Coolant Temperature

• Battery Voltage

• Fuel Type Selection

• Vehicle Security

• Gear Indicator

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 electromagnetic

radiation >= 10 V/m.

The PIDD also offers GPS mapping and Bluetooth® connectivity for compatible smartphones/devices. This feature will display text messages and missed phone calls on the display screen. The PIDD submenus and most display features are controlled by either the five button keypad on the PIDD or by the MODE/SET the left hand control. Please see your PIDD Owner’s Manual for more information. This manual is frequently updated for accuracy and new features.

switch on

Page 64

GAUGE

FUEL TYPE SELECTION

When using the recommended 91 non-ethanol gasoline, always select the 91 NON-ETHANOL setting. When using ethanol, MTBE, or other forms of oxygenated gasoline, the fuel type must be changed to NON-PREMIUM/ ETHANOL in the gauge.

IMPORTANT

Whenever in doubt of your fuel purchase, use the NON-PREMIUM / ETHANOL

mode.

FUEL TYPE SELECTION

When using the recommended 91 nonethanol gasoline, always select the 91 NON-ETHANOL setting. When using ethanol, MTBE, or other forms of oxygenated gasoline, the fuel type must be changed to NON-PREMIUM/ ETHANOL in the gauge.

IMPORTANT

Whenever in doubt of your fuel purchase, use the NON-PREMIUM / ETHANOL

mode.

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. Press and hold the center

3. Press and release the MODE button until FUEL TYPE is displayed in the information display area.

4. Press and release the SET button to toggle through available options until the desired fuel type is displayed in the information display area.

5. To exit Options Menu, Press and release the MODE button until EXIT appears in the information display area.

6. Press and release the SET button to exit. The fuel type being displayed is the active fuel type.

button to enter the Options Menu.

Page 65

POLARIS INTERACTIVE DIGITAL DISPLAY (PIDD)

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

ENGINE OVERHEAT INDICATORS

OVER-TEMPERATURE INDICATOR (STANDARD CLUSTER)

immediately.

GAUGE

OVERHEAT WARNING (PIDD)

Stop the engine immediately.

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

located

Page 66

GAUGE

600/800 HO MODELS ENGINE TEMPERATURE PROTECTION MODES

Hot Lamp Threshold*

ON Lamp illuminates: Idle = 201° F (94° C), WOT = 185° F (85°

FLASHING Lamp Flashes, Engine Turns Off: Idle = 215.6° F (102° C),

WOT = 201° F (94° C)

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

ENGINE-COOLING ACTIONS

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

• Drive in loose snow.

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

Add coolant if the level is low.

• Stop the engine and allow it to cool down.

• Ensure radiator is clean and free of debris.

NOTICE

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

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

Page 67

THE PERFECT FIT

SUSPENSION QUICK SET-UP GUIDE

The front and rear suspensions on your snowmobile are easy to adjust. Just remember three simple steps:

Step 1: Ride your snowmobile.

Ride the snowmobile in various terrain to fully experience the existing suspension settings before making any adjustments.

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

After riding, you should be able to determine if the snowmobile needs more or less transfer.

• For more transfer, decrease the torsion spring preload.

• For less transfer, increase the torsion spring preload.

If you prefer your snowmobile has lighter steering, decrease the torsion spring preload or increase the front track shock spring preload.

Step 3: Adjust shock clickers (if equipped) for ride quality.

For models equipped with monotube shocks, always adjust the rear torsion spring preload to enhance bottoming resistance.

For models with shock clickers, you can adjust the clickers to control bottoming and adjust ride comfort.

• Turn a clicker counter-clockwise to decrease damping for a softer ride.

• Turn a clicker clockwise to increase damping for a stiffer ride and less bottoming.

NOTE

Always adjust the clicker at least one click below full stiff (full clockwise) or

shock damage could occur.

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

NOTE

Adding traction components, such as traction studs or additional ski skag

carbides, or changing the factory equipped track, could change handling

characteristics. Addition setup may be required.

Page 68

THE PERFECT FIT

SHOCK LOCATIONS

Rear Track Shock

Front Track Shock

Front IFS Shock

SHOCK COMPRESSION DAMPING

The primary adjustment for overall vehicle balance is torsion spring preload. Perform this adjustment first. After adjusting torsion spring preload to your satisfaction, compression damping adjustments can be made to control ride quality and bottoming resistance.

Compression damping can be adjusted at the front suspension and at the front and 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) counter-clockwise two clicks, then test ride. Repeat the adjustment until the desired ride quality is achieved.

Page 69

TORSION SPRING ADJUSTMENTS

THE PERFECT FIT

To adjust rear torsion spring preload, rotate the three-position camqusing the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more effort. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information.

NOTE

Adding 1+1 seat, or additional cargo may affect handling and require a spring

rate change.

TORSION SPRING SETTING

Low Rider(s) and gear =140-180lb

Medium Rider(s) and gear = 180-220lb

RECOMMENDED USAGE

If less than 140, use the optional spring chart for softer springs.

High Rider(s) and gear = 220-260lb

If above 260, use the optional spring chart for heaver springs.

Page 70

THE PERFECT FIT

OPTIONAL SPRINGS

If the correct balance cannot be obtained by adjusting the stock springs, please install the appropriate optional heavy or light springs listed below.

PART NUMBER SPRING TYPE DESCRIPTION

7043859–329 Spring, Torsion LH Light Duty

7043860–329 Spring, Torsion RH Light Duty

7045207–329 Spring, Torsion LH Heavy Duty

7045208–329 Spring, Torsion RH Heavy Duty

7045209–329 Spring, Torsion LH Extra Heavy Duty

7045210–329 Spring, Torsion RH Extra Heavy Duty

REAR TRACK SHOCK FACTORY CLICKER SETTINGS

Indy XC

MODEL FACTORY CLICKER SETTING

(FROM FULL STIFF)

Page 71

THE PERFECT FIT

FRONT TRACK SHOCK SPRING SETTINGS

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

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

NOTICE

Never adjust spring preload to an installed length longer than the factory length

or shorter than the minimum length as shown in the following chart. Damage to

the suspension could result. When decreasing preload, make sure at least two

turns of preload are holding the retainer against the spring.

INDY SP

INDY XC

FRONT TRACK SHOCK SPRING SETTINGS

FACTORY SPRING MAXIMUM

INSTALLED LENGTH

INDY SP 1.25" (3.2 cm) 0.75" (1.9 cm)

INDY XC 1.5" (3.8 cm) 1" (2.5 cm)

MINIMUM INSTALLED

LENGTH

FRONT TRACK FACTORY CLICKER SETTINGS

MODEL CLICKER SETTING

(FROM FULL HARD)

INDY SP N/A

INDY XC

Page 72

THE PERFECT FIT

FRONT SUSPENSION (IFS) SHOCK ADJUSTMENTS (IF EQUIPPED)

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

To reset IFS clickers, rotate the clicker to full stiff, and then back off the same number of clicks for each shock.

IFS SHOCK SPRING SETTINGS

FACTORY SPRING FACTORY

INSTALLED LENGTH

INDY SP 10.75” (27.3 cm) 10” (25.4 cm)

INDY XC 10” (25.4 cm) 10” (25.4 cm)

MINIMUM INSTALLED

LENGTH

IFS REMOTE RESERVOIR SHOCK FACTORY CLICKER SETTINGS

MODEL CLICKER SETTING

(FROM FULL HARD)

INDY SP N/A

INDY XC 12

CORNERING ADJUSTMENTS

To improve cornering ability, remove up to 1/2" of preload from factory IFS spring setting. Trade-off for removing 1/2" of preload will add steering effort.

Page 73

LIMITER STRAP ADJUSTMENT

The front torque arm limiter strap is set at positionq.

POLARIS recommends leaving the limiter strap length at position maintain the optimum ride characteristics of the snowmobile. Riders who desire less ski pressure and more weight transfer toward the rear of the snowmobile can lengthen the limiter strap by changing to position

1. Loosen the lock nut.

2. Adjust the limiter strap.

3. Tighten the lock nut.

THE PERFECT FIT

TORQUE

16 ft-lbs (21 Nm).

Page 74

THE PERFECT FIT

HANDLE BAR EXAMPLES

HANDLEBAR COMPONENT FASTENER TORQUES

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.

COMPONENT TORQUE

DO NOT OVER-TIGHTEN

Left Handlebar Control Block 20 in-lbs (2.3 Nm)

Brake Lever / Master Cylinder

Torque the front screw first, then torque the screw next to the reservoir.

Upper / Lower Riser Clamps 14.8 ft-lbs (20 Nm)

Throttle Lever Block Set Screw 27 in-lbs (3.1 Nm)

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

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

Riser Install with the “FWD” stamp facing

70 in-lbs (7.9 Nm)

toward the hood

Page 75

COMPONENT TORQUE

DO NOT OVER-TIGHTEN

THE PERFECT FIT

Not Shown

Hand Guard Mounts (if applicable) Hand-Tight

Mountain Hoop Bar (if applicable) 10 ft-lbs (13.6 Nm)

HANDLEBAR ANGLE

Handlebar angle can be adjusted to suit rider preference.

1. Loosen the four bolts on the top riser block

2. Adjust the handlebar upward or downward to the desired angle. Be sure the

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

NOTICE

Do not stretch wires while adjusting the controls. Stretching the wires could

damage the handwarmers.

3. Tighten the bolts.

TORQUE

14.8 ft-lbs (20 Nm)

Page 76

THE PERFECT FIT

RISER ANGLE

Riser angle can be adjusted to suit rider preference.

1. Loosen the four bolts on the bottom of the adjuster block pry the blocks apart with a screwdriver.

2. Adjust the riser forward or rearward to the desired position.

3. Tighten the bolts to 14.8 ft-lbs (20 Nm).

. If necessary,

ADJUSTABLE RISER (IF EQUIPPED)

To adjust the riser (if equipped), do the following:

1. Release the riser clamp

2. Adjust the handlebar upward or downward to the desired height.

3. Secure the riser clamp

Periodically inspect the torque of the upper/lower handlebar clamp fasteners, and slide fasteners.

TORQUE

Handlebar Clamp Fastener Torque:

16 ft-lbs (21 Nm)

ROX Slide Fastener Torque:

16 ft-lbs (21 Nm)

Adjuster Cranks:

Hand Tight

Page 77

THE PERFECT FIT

LEFT HAND CONTROL ALIGNMENT

1. Loosen the brake master cylinderAmounting screws and move it away from the left hand controlB.

CAUTION

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

components.

2. Loosen the four left hand control mounting screws.

3. Move the control block to the desired position.

NOTE

If the control is loose and was inadvertently moved without loosening the

screws, move the control block slightly to the left or right to relocate the pins.

Page 78

THE PERFECT FIT

4. Tighten the screws to specification in the sequence shown in the image. Do not over-torque.

TORQUE

24 in-lbs (2.7 Nm)

5. Return the master cylinder to its specified position. Make sure the clamp will not pinch the brake light signal wire. Tighten the clamp screws to specification beginning with the front screw first, then the screw next to reservoir. Do not over-torque.

TORQUE

70 in-lbs (7.9 Nm)

HANDLEBAR COMPONENTS

Refer to the following illustration and measurements to position handlebar components at factory-specified locations.

.011 in. (3 mm)

6.65 in. (169 mm)

10 in. (254 mm)

.47 in. (12 mm)

6.7 in. (170 mm)

.08 in. (2 mm)

Page 79

THE PERFECT FIT

THROTTLE BLOCK ALIGNMENT

NOTICE

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

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

2. Move the control block to the desired position.

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

4. With the engine off, test throttle lever movement after tightening the screw. See page 93.

TORQUE

27 in-lbs (3 Nm)

ENGINE STOP SWITCH ALIGNMENT

CAUTION

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

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

2. Move the switch to the desired position.

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

TORQUE

12 in-lbs (1.4 Nm)

Page 80

THE PERFECT FIT

TRACTION PRODUCTS

TRACK STUDDING

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

When studded tracks are used, increased wear to the brake pads will result from increased braking and requires increased brake inspection intervals.

Installing studs can also cause the track to stretch more than a non-studded track. For this reason, POLARIS recommends inspecting track tension more often and setting the tension at the preferred measurement.

Always adhere to the manufacturer’s stud maintenance procedures and stud nut torque specifications.

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

STUDS

Track damage resulting from improperly installed or maintained studs is not covered under warranty. Use only POLARIS-approved traction products on your snowmobile. See your dealer for more information about installing studs and/or carbides.

CAUTION

Failure to heed the following recommendations will result in tunnel or track

damage:

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

• Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the specification to prevent heat exchanger damage. The center of the stud must be at least 1 1/8 inch (2.9 cm) from any edge of the track, including track window.

• Studding the outside band of the track diminishes durability.

• Polaris does not recommend studs on the outside band of the Storm 150 track. Damage will occur.

The AXYS Indy 129 chassis requires stud protection kit 2883572 to be installed before installing studs or chassis damage will occur. This stud protection kit will protect against chassis damage with the following track/stud combinations.

Page 81

THE PERFECT FIT

• 1.325” Polaris/Woody’s studs installed in a Ripsaw II 1.25” or Cobra 1.352” track .

• 1.575” Polaris/Woody’s studs installed in a Storm 150 track, center band only.

MAXIMUM PENETRATION

POLARIS

Studs

Signature Series

Stud

Length

in.

1.325 3.4 .375 .95 .27 .7 1.58 4.0 YES

1.45 3.7

1.25-Inch (3.2 cm)

Track

in.

- - - -

1.352-Inch (3.4 cm)

Cobra

Track

in.

Overall

Installed

Height

in.

1.7 4.3 NO

Recom-

mended

for AXYS

models

CARBIDE SKAGS

A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper steering and control. See page 126.

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

Page 82

Page 83

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 in the referenced sections.

ITEM SEE SECTION

Drive Belt page 118

Steering System page 85

Recoil Rope page 86

Coolant Level page 110

Chaincase Oil Level (if equipped) page 103

Injection Oil Level page 92

Parking Brake Lock/Brake Lever/ Brake System

Auxiliary Shut-Off Switch (Engine Stop Switch)

Ignition Switch page 33

Headlight/Taillight/Brakelight page 86

Suspension Mounting Bolts page 82

Skags (Wear Bars) page 126

Ski Saddle and Spindle Bolts page 82

Hood and Side Panel Fasteners page 106

Throttle Lever/Safety Switch page 83 and page 83

page 83, page 84, and page 114

page 93

Rear Wheel Idler Bolt page 121

Tether Switch/Strap (if equipped) page 86

Track Alignment/Condition page 85 and page 122

Rail Slide Condition page 127

Page 84

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 SECTION

Check suspension mounting bolts for tightness.

Check rear idler wheel bolt for tightness.

Check rear idler adjusting bolt locknuts for tightness.

Check front torque arm limiter strap condition.

Check rail slide condition. page 127

Check track tension. page 121

Check ski runner/skag condition. page 126

Check ski spindle bolts for tightness.

Check tie rod end nuts for tightness.

page 121

Page 85

PRE-RIDE INSPECTIONS

BEFORE STARTING THE ENGINE

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

WARNING

Operating the vehicle with worn, damaged, or malfunctioning components

could result in serious injury or death. Never start the engine without checking

all vehicle components to be sure of proper operation.

READ AND UNDERSTAND YOUR OWNER'S MANUAL

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

THROTTLE LEVER

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

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

THROTTLE SAFETY SWITCH

Test the throttle safety switch system before the snowmobile is operated.

BRAKES

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

BRAKE LEVER TRAVEL

Squeeze the brake lever. It should move no closer to the handgrip than 1/2 inch (1.3 cm) indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page . Your dealer can assist.

. A smaller distance

Page 86

PRE-RIDE INSPECTIONS

LEVER FEEL

If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See page 115.

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.

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

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.

NOTE

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

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

The 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.

Page 87

PRE-RIDE INSPECTIONS

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.

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.

Page 88

PRE-RIDE INSPECTIONS

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, your POLARIS dealer can provide a replacement.

START THE ENGINE AND CHECK

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See page 83.

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.

Page 89

OPERATION

STARTING THE ENGINE

CAUTION

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

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

the engine is running.

1. Turn the key to the ON position.

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

3. If equipped with electric start, turn the key to START to crank the engine. Release the key to the ON position when the engine starts.

4. If not equipped with electric start, grasp the starter handle and pull slowly until the recoil engages; then pull abruptly to crank the engine.

5. If the engine does not start after several attempts, slightly depress the throttle no more than 1/4 inch (2.54 cm) open while cranking the engine. When the engine starts, immediately release the throttle.

CAUTION

To avoid injury and/or engine damage, do not operate the electric starter or

pull-rope starter while the engine is running.

NOTICE

Operating the vehicle immediately after cold starting could cause engine

damage. Allow the engine to warm up for several minutes before operating the

vehicle. If cold drive-away is attempted, the engine RPM may stumble slightly

to protect the engine.

RESTARTING AN ENGINE

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

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

2. Turn the key to the OFF position.

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

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

Page 90

OPERATION

5. Release the throttle.

6. Restart the engine using the normal starting procedure.

BREAK-IN PERIOD

ENGINE BREAK-IN

The recommended break-in period is the time required to use the first full tank of fuel.

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

The engine management system utilizes both a fuel injector break-in period and oil pump enrichment program. The duration of these break-in programs is independent of each other and is timed out based on engine run time. Regardless of these automatic engine break-in and enrichment features, the following engine break-in procedures must be performed when the engine is new or overhauled.

NOTE

During this period of increased oiling, sled performance will not be affected and

you should ride normally.

BREAK-IN FUNCTION ENGINE

RUN TIME

Fuel Injectors

600 Models Oil Pump Enrichment

Period

800 Models Oil Pump Enrichment

Period

* = Total engine run time above 5,500 RPM

OIL RECOMMENDATIONS

First Tank of Fuel: POLARIS VES 2-Cycle Oil

2 Hours Additional fuel

5 Hours *

18 Hours *

DESCRIPTION

Enriched oil supply

to engine

After Break-in: POLARIS VES 2-Cycle Oil

Extreme Arctic Conditions, sustained temperature is at or below -40° F (-40° C)

VES Extreme 2-Cycle Oil

Page 91

OPERATION

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.

NOTICE

Use of any lubricants other than those recommended by POLARIS may cause

serious engine damage. We recommend the use of POLARIS lubricants for

your vehicle.

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

OIL INJECTION SYSTEM

Always check and fill the oil bottle when refueling.

NOTICE

Serious engine damage can occur without the proper lubrication. Check the oil

bottle level often during the first tank of fuel. If the oil level doesn't go down,

your dealer can assist.

DRIVE BELT BREAK-IN

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

New drive belts should be washed with warm, soapy water and allowed to air dry prior to use.

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

Page 92

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.

Page 93

OPERATION

FUEL

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

• Always turn off the engine before refueling.

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

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

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

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

WARNING

The engine exhaust from this product contains chemicals known to cause

cancer, birth defects or other reproductive harm. Operate this vehicle only

outdoors or in well-ventilated areas.

FUEL RECOMMENDATION

For peak performance, POLARIS recommends the use of 91 octane fuel or higher, with no ethanol. 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.

IMPORTANT

Do not use fuel containing more than 10% ethanol. Never use E85 or 88 E15

fuel in your snowmobile.

NOTICE

Operating with obstructed fuel systems will result in serious engine damage.

Perform maintenance as recommended. Prolonged exposure to petroleum

based products may damage paint. Always protect painted surfaces when

handling fuel.

Page 94

OPERATION

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.

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

OIL

LOW OIL LEVEL

Always maintain the oil level between the “add” mark and the bottle neck. Do not fill the bottle neck.

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. Your POLARIS dealer can assist with recommended replacement parts.

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.

Page 95

OPERATION

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, your authorized POLARIS dealer can perform this 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.

ENGINE STOP SWITCH

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

Page 96

OPERATION

WARNING

Operating the snowmobile with a faulty throttle safety switch can result in

serious injury or death in the event of an accident. If the throttle safety switch

does not shut off the engine during a carburetor/throttle system malfunction,

immediately push down the engine stop switch. Do not start the engine again

until the malfunction has been corrected by your 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.

POLARIS ELECTRONIC REVERSE CONTROL (PERC)

WARNING

Improper reverse operation, even at low speeds, may cause loss of control,

resulting in serious injury or death. Damage will occur to the chaincase or

transmission if shifting is attempted when the engine is operating above idle

speed.

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

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

Electronic reverse will activate only if the engine RPM is below 3000.

CAUTION

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

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

the engine is running.

Page 97

OPERATION

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 5000 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.

CAUTION

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

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

the engine is running.

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

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

EMERGENCY STOPPING

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

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

Page 98

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.

Page 99

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. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions related service, however equivalent parts may be used for such service. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering with emission controls is prohibited by federal law.

EMISSION CONTROL LABEL

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

EMISSION CONTROL MAINTENANCE REQUIREMENTS

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

OWNER'S RESPONSIBILITIES

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

NON-IONIZING RADIATION

This vehicle emits some electromagnetic energy. People with active or nonactive 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.

Page 100

MAINTENANCE

POLARIS RECOMMENDED MAINTENANCE PROGRAM

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.

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 169.

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, your authorized POLARIS dealer can provide any needed service.