Polaris 800 switchback assault, 800 RMK 2011, 800 PRO-RMK 2011, 800 RMK ASSAULT 2011 Owner's Manual

PMS 419

Snowmobile Owner's Manual

for Maintenance and Safety

800 SwitchBack

Assault

Modifications to this snowmobile are not recommended

and may result in voided warranty coverage.

Please read the warranty section of this manual carefully.

IMPORTANT NOTICE TO OWNER

WARNING

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

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

WARNING

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

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

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone [phone]
Part No. 9923248 Rev 01
Printed in USA

*9923248 *

PMS 419

1

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polarisindustries.com for the latest news, new product introduc­tions, upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and
recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER

®

utility vehicles

• Victory Motorcycles

®

• Low emission vehicles (LEVs)
We believe POLARIS sets a standard of excellence for all utility and

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

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

®

(MSD)

technician.
Your POLARIS dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your ser­vice needs during, and after, the warranty period.

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

2

POLARIS, THE WA Y OUT, SWITCHBACK and ASSAUL T are registered trademarks
of POLARIS Industries Inc.

Copyright 2010 POLARIS Sales Inc. All information contained within this publication
is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies may result between the actual vehicle and the information presented in this publi­cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

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

Printed in U.S.A.
2011 800 SWITCHBACK ASSAULT Owner's Manual
P/N 9923248

3

TABLE OF CONTENTS

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

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

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

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

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 42

This section includes suspension set-up information and explains how to
make additional suspension adjustments for the perfect riding experi­ence.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 46

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 100

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 101

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 115

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

4

5

INTRODUCTION

Important Notes for Owners and Drivers

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

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

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

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

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

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

6

INTRODUCTION

Preservation of the Environment

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

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

Noise Level

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

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

Air Pollution

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

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

7

INTRODUCTION

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

Tunnel VIN (right side of tunnel): ____________________________________________

Engine Serial Number (on recoil housing): _____________________________________

Key Number: ____________________________________________________________

Tunnel VIN

8

SAFETY

Operator Safety

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

The safety alert symbol indicates a potential personal injury hazard.

WARNING

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

CAUTION

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

NOTICE

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

9

SAFETY

Operator Safety

Follow the recommended maintenance program beginning on page 67
of this manual to ensure that all critical components on the snowmobile
are thoroughly inspected by your dealer at specific mileage intervals.

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

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

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

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

WARNING

10

SAFETY

Operator Safety

Stay Clear of Track

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

WARNING! Serious injuries may result if
hands, feet, or clothing become entangled
in the track. Be alert when riding, and
remain properly seated to stay clear of the
track. Never hold the snowmobile up or
stand behind it while warming up the track.
A loose track or flying debris could cause
serious injury or death. We recommend
having your dealer perform all track service
and alignment procedures.

Stay Clear of Engine

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

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

Riding Position

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

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

NO STEP

11

SAFETY

Operator Safety

Riding Apparel

Helmet

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

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

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

Eye Protection

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

Clothing

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

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

E

4

051039

0006.31

12

SAFETY

Operator Safety

Disabled Operators

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

Survival Preparation

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

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

• Spare Drive Belt • Winter Survival Kit

• Extra Set of Spark Plugs • Trail Map

•Tow Rope •First Aid Kit

• Extra Oil • To ol Kit

• Fuel Deicer

13

SAFETY

Operator Safety

Rider Capacity

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

Excessive Speed

WARNING! High speed driving, especially at night, could result in serious injury

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

Always observe all state and local laws governing snowmobile opera­tion and speed limits. Always be alert and pay attention to the trail
ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling
about 60 feet (18 m) per second. If you look back for only two seconds,
your snowmobile will travel about 120 feet (36 m). If your speed is 60
MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in
two seconds.

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

14

SAFETY

Operator Safety

Driver Awareness

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

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

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

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

RR

15

SAFETY

Operator Safety

Avalanches

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

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

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

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

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

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

16

SAFETY

Operator Safety

Ice and Snow Build-up

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

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

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

Driving on Slippery Surfaces

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

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

Inadequate Snow Conditions

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

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

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 surfa ce s . Avoid
operating for prolonged periods on ice, hard-packed surfaces or roads.

Operating in Deep Snow

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

17

SAFETY

Operator Safety

Driving Downhill

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

WARNING! When driving on long downhill stretches, pump the brakes. Riding
the brakes may cause the brake system to overheat, which may result in brake
failure. Excessive or repetitive use of the brakes for high speed stops will also
cause an overheated brake system. This condition may lead to a sudden loss of
brakes and/or fire and may result in serious injury or death.

Driving in Hilly Terrain

WARNING! Climbing a hill or crossing the face of a slope may result in loss of

balance and snowmobile rollover, causing serious injury or death. Use caution
and good judgement when driving in hilly terrain.

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

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

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

18

SAFETY

Operator Safety

Drive Belt

Do not operate the engine with the drive belt removed.

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

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

damage to the engine.

Intake Silencer

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

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

removed.

Clutches

Do not attempt to service the clutches.

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

Cold Weather Drive-Away

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

Maneuverability

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

19

SAFETY

Operator Safety

Driving Responsibly

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

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

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

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

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

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

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

20

SAFETY

Operator Safety

Windchill/Temperature Charts

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

WINDCHILL CHART (_F)

WINDCHILL CHART (_C)

Wind

Speed

in

MPH

Actual Thermometer Reading (_F)

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

Equivalent Temperature (_F)

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

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

5 3631251913 7 1 -5-11-16

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

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

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

15 32 25 19 13 6 0 -7 -13

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

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

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

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

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

30 28 22 15 8 1 -5 -12

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

35 28 21 14 7 0 -7 -14

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

40 27 20 13 6 -1 -8 -15

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

45 26 19 12 5 -2 -9 -16

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

50 26 19 12 4 -3 -10 -17

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

55 25 18 11 4 -3 -11

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

60 25 17 10 3 -4 -11

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

Frostbite in >>

30 min. 10 min. 5 min.

Wind

Speed

in

KPH

Actual Thermometer Reading (_C)

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

Equivalent Temperature (_C)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Frostbite in >>

30 min. 10 min. 5 min.

21

SAFETY

Safety Labels and Locations

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

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

Clutch Warning

This warning label is found on the oil bottle:

WARNING
Do not operate engine with

hood or side panels open.
Do not attempt adjustment

with engine running.
Do not operate engine with

the clutch guard removed.
Never run engine with drive

belt removed.
Never service clutches your-

self. See your dealer.

Pressure Cap Warning

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

WARNING
Do not open hot. Test or replace when changing coolant. Press

down and turn to release cap. 13 PSI

22

SAFETY

Safety Labels and Locations

“No Passenger” Warning

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

WARNING
This vehicle is designed for operator only. NO PASSENGER

Reverse Warning

The reverse warning label is located on the console:

WARNING
Reverse operation, even at low speeds, can cause loss of control

resulting in serious injury or death. To avoid loss of control,
always:

• Look behind befo re and while backing up.

• Avoid sharp turns.

• Shift to or from reverse only when stopped.

• Apply throttle slowly.
NOTE: For more information, see Owner's Man ua l.
If electric reverse:

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

• Push button again to return to forward.

Reverse
Warning

“No Passenger”

Warning

23

SAFETY

Safety Labels and Locations

Track Warning

The track warning label is on the
rear tunnel:

WARNING
Stay clear of track. Do not sit on

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

Hot Surface Warning

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

WARNING
Hot Surface
Do Not Touch
Burns may result. Entire top of tunnel may be hot. Install only

accessories specifically approved for this model by POLARIS. Do
not place clothing, bags or cargo on tunnel. Do not cover this
label.

Track

Warning

Hot Surface

Warning

24

SAFETY

Safety Labels and Locations

Operation Warning

The operation warning label is also located on the console.

WARNING

• To avoi d 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 adeq uate
clothing while operatin g thi s ve hicle.

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

(continued on next page)

Operation Warning

25

SAFETY

Safety Labels and Locations

Operation Warning

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

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

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

• 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.

26

FEATURES

8

13

5

6

7

12

11

2

1

3

4

10

9

1. Nosepan

2. Skis

3. Front Bumper

4. Hood

5. Headlight

6. Windshield (accessory)

7. Handlebar

8. Operator Seat

9. Taillight

10. Rear Bumper

11. Snow Flap

12. Suspension

13. Track

14. Side Panel

15. Side Panel Fasteners

15

14

27

FEATURES

1. Fuel Filler Cap

2. Electronic Reverse Button

3. Brake Lever

4. Parking Brake Lock

5. Instrument Cluster

6. Ignition Switch

7. Engine Stop Switch

8. Throttle Control

9. Recoil Starter Handle

10. Handlebar Grip Warmer
Switch

11 . Headlight Dimmer Switch

12. MODE/SET Switch

13. Thumbwarmer Switc h

1

6

7

8

9

5

3

4

2

12 11 10

28

FEATURES

Storage Bag/Tool Kit

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

Adjustable Headlights

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

Accessories

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

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

• Non-compliance with government/industry requirements

• Voiding of warranty

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

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

Storage Bag

Up

Down

29

FEATURES

Fuel Resistor

This snowmobile is equipped with a feature that allows the engine con­troller to select the proper operating software based on the type of fuel
being used. See pages 57-58 for fuel information and recommendations.

The ECU fuel designation connector must have the “NON-ETHANOL
160 OHM” resistor installed when using non-ethanol gasoline.

When using ethanol, MTBE, or other forms of oxygenated gasoline, the
“10% ETHANOL 24 OHM” resistor must be connected.

Whenever in doubt of your fuel purchase, use the “10% ETHANOL 24
OHM” resistor as a safeguard.

The resistor is installed into the wiring harness on the left side of the
snowmobile just above the top of the oil bottle (see photo).

NOTICE: Engine damage may occur if ethanol fuel is used while the non-eth a-

nol fuel resistor is installed. The check engine light may also display in
this condition as this could cause detonation.

10% ETHANOL

24 OHM

NON-ETHANOL

160 OHM

Resistor

NON-ETHANOL GASOLINE

91+ OCTANE

(Maximum Performance)

ETHANOL, MTBE, OR OTHER

OXYGENATED GASOLINE

(Factory Delivery)

ANY FUEL WITH ETHANOL

or LESS THAN 91 OCTANE

(87 Octane Minimum)

30

FEATURES

Detonation Elimination Technology (DET)

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

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

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

Check Engine Light Indicates

Solid or Flickering Excessive detonation detected

Steady Flashing Severe detonation detected, RPM will be limited

31

FEATURES

Detonation Elimination Technology (DET)

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

DET Troubleshooting

Cause of DET Activation Solution

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

resistor installed

V erify correct fuel resistor for fuel type

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

Ethanol fuel

Do not add deicers or additives that

contain any form of alcohol while

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

32

FEATURES

Instrument Cluster

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

NOTICE: Certain products will damage

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

Rider Information

Center

Check Engine

Indicator

High Beam

Indicator

Low Oil

Indicator

Over-

Temperature

Indicator

Park Brake

Indicator

Reverse

Indicator

MODE

Button

SELECT

Button

Mode/Set Switch

33

FEATURES

Instrument Cluster

Indicators

Check Engine Indicator

This indicator appears if an EFI-related fault occurs. Do not operate the
snowmobile if this warning appears. Serious engine damage could
result. See your dealer. See page 40 for diagnostic code definitions.

Over-Temperature Indicator

This indicator illuminates to alert the operator that the engine is over­heating. The operator should take action to cool the engine. See page 79.
If the indicator flashes, continued operation could result in serious
engine damage. Stop the engine immediately.

Low Oil Indicator

The low oil indicator light may flicker at times due to oil movement in
the bottle, but when the light comes on and remains on, add the recom­mended oil before further operation. See page 59.

High Beam Indicator

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

Parking Brake Indicator

This indicator illuminates when the parking brake is engaged. It will
also illuminate when the service brake is in use. See page 50.

Reverse Indicator

This indicator flashes when the transmission is in reverse. See page 63.

34

FEATURES

Instrument Cluster

Rider Information Center

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

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

The information center is set to display standard units of measurement
for distance and temperature. To change to metric units, see page 38.

2

5

3

4

1

35

FEATURES

Instrument Cluster

Rider Information Center

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

or vehicle speed (whichever is not displayed in the speed display),
engine temperature and maximum vehicle speed. To change the dis­play, see page 36.

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

speed or engine speed. To change the display, see page 36.

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

Trip A, T rip B and engine hours. To change the display , see page 37.

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

low.

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

and play back engine speed, vehicle speed and throttle position sen­sor information for up to three minutes. The playback icon flashes
while recording. See page 37.

36

FEATURES

Instrument Cluster

Rider Information Center

Speed Display Area

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

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

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

Information Display Area

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

37

FEATURES

Instrument Cluster

Rider Information Center

Odometer/Engine Hour Display Area

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

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

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

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

Playback Function

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

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

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

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

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

38

FEATURES

Instrument Cluster

Rider Information Center

Standard/Metric Display

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

Change Method 1

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

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

change.

Change Method 2

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

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

change.

39

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Display Mode

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

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

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

Use the following procedure to view active codes.

1. Do not stop the engine.

2. With the brake engaged, press and release the SELECT button or
SET switch to toggle to the diagnostic display mode. When a code
is active, the diagnostic display mode will appear immediately fol­lowing the engine hour display.

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

will begin to flash.

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

• The 2-6 digit suspect parameter number (SPN) in the information display
area indicates which component is generating the fault code.

• The 1-2 digit failure mode indicator (FMI) number in the odometer area
indicates the fault mode, such as open or short circuit.

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

5. See page 40 for code definitions and failure descriptions.

40

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions

Open Load:

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

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

Short-to-Ground:

The wire is shorted to ground between the electronic

control unit and the item listed in the chart.

Shorted Load:

The wires leading to the item listed in the chart are

shorted together, or the item has shorted internally.

Short-to-Battery:

The wire leading from the item listed in the chart to

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

Diagnostic Codes

Component Condition SPN FMI

Throttle Position Sensor

Voltage Too High 51 3
Voltage Too Low 4

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

Voltage Too Low 4
Barometric Pressure Sensor

Voltage Too High 108 3

Voltage Too Low 4
Engine Temperature Sensor

Voltage Too High 110 3

Voltage Too Low 4

Temperature Too High 16

Engine Overheat Shutdown 0

Temperature Above Normal Range 15
Alternator Power Supply

Potential (DC Chassis Voltage)

Voltage Too High 167 3

Voltage Too Low 4
Exhaust Temperature Sensor

Voltage Too High 173 3

Voltage Too Low 4

41

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions.

Diagnostic Codes

Component Condition SPN FMI

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

Driver Circuit Short to B+ 3

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

Driver Circuit Short to B+ 3
Knock Sensor 1 Voltage Too Low 731 4
Ignition Coil Primary Driver 1 (MAG) Driver Circuit Open/Grounded 1268 5
Fuel Pump Driver Circuit Driver Circuit Open/Grounded 1347 5
Knock Level Cylinder 1 (MAG) Maximum Detonation

Correction Limit Reached

1352 0

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

Correction Limit Reached

1353 0

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

TMAP Sensor Power)

Voltage Too Low 3509 4
Sensor Supply Voltage 2 (Ground

Speed Sensor)

Voltage Too Low 3510 4
ECU Output Supply Volt age 2 (Injec-

tion Supply PWR)

Voltage Too High 3598 3

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

Voltage Too Low 4

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

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

Driver Circuit Short to B+ 3
Fuel Type Selected Voltage Too High 524007 3

Voltage Too Low 4

Signal Out Of Range 2

42

THE PERFECT FIT

Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

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

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

TIP:The rear bumper may need to be

lifted upward slightly to fully extend
the suspension.

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

To determine sag, commonly referred to as ride-in, subtract measure­ment Y from X (Sag=X-Y). Adjust sag by rotating the torsion spring
preload cams located on the rear torque arm. See illustration. The ideal
amount of sag for this rear suspension is five inches (12.7 cm) (X-Y=5
in./12.7 cm).

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

X

Y

43

THE PERFECT FIT

Suspension Adjustments

Torsion Spring Preload

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

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

Soft (long end of cam to front)
Medium (short end of cam up)
Firm (long end of cam up)

Soft Medium

Firm

44

THE PERFECT FIT

Suspension Adjustments

Shock Compression Damping

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

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

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

Stiffer Softer

Rear Track

Shock

Front Track

Shock

45

THE PERFECT FIT

Suspension Adjustments

Independent Front Suspension and Front Track Shock
Spring Preload

Factory settings, combined with user adjustments to the rear track shock
spring, should be all that’s necessary to provide the best riding experi­ence for most riders. The primary adjustment for overall vehicle balance
is torsion spring preload. Perform this adjustment first. See page 43.

After adjusting torsion spring preload, and if desired, additional adjust­ments can be made to the independent front suspension and front track
shock preload.

When adjusting the front suspension, be sure the springs

on both sides of the vehicle are at the same adjustment.

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

To improve corner stability, increase front suspension (IFS) spring pre-

load by 1-2 turns on both sides of the vehicle.

Handlebar Adjustments

Handlebar Angle

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

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

3. Tighten the bolts.

Loosen

Bolts

46

PRE-RIDE INSPECTIONS

Pre-Ride Checklist

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

Item See Page

Drive Belt Condition 87
Steering System 51
Recoil Rope 51
Coolant Level 78
Chaincase Oil Level 73
Injection Oil Level 59
Parking Brake Lock/Brake Lever/Brake System 49, 50, 82
Auxiliary Shut-Off Switch (Engine Stop Switch) 52
Ignition Switch 52
Headlight/Taillight/Brakelight 52
Suspension Mounting Bolts 47
Skags (Wear Bars) 97
Ski Saddle and Spindle Bolts 47
Hood and Side Panel Fasteners 71
Throttle Lever/Safety Switch 60, 61
Rear Wheel Idler Bolts 93
Tether Switch/Strap (if equipped) 52
Track Alignment/Condition 51, 94
Rail Slide Condition 97

47

PRE-RIDE INSPECTIONS

Pre-Ride Suspension Inspection

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

Item See Page

Check suspension mounting bolts for tightness. -­Check rear idler wheel bolts for tightness. 93
Check rear idler adjusting bolt locknuts for tightness. -­Check front torque arm limiter strap condition. -­Check rail slide condition. 97
Check track tension. 92
Check ski runner/skag condition. 97
Check ski spindle bolts for tightness. -­Check tie rod end nuts for tightness. --

48

PRE-RIDE INSPECTIONS

Before Starting the Engine

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

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

Read and Understand Your Owner's Manual

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

n Throttle Lever

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

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

n Throttle Safety Switch

T est the throttle safety switch system before the snowmobile is operated.
See page 60.

49

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Brakes

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

Brake Lever Travel

Squeeze the brake lever. It
should move no closer to the
handgrip than 1/2I (1.3 cm).
A smaller distance indicates
low brake fluid level or air in
the hydraulic system. Refer
to the brake bleeding infor­mation on page 84 or see
your dealer for service.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 83.

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

1

/

2

I

(

1

.

3

c

m

)

50

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Parking Brake Lever Lock

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

1. Brake Lever

2. Parking Brake Lever Lock

3. Master Cylinder
Reservoir/Cover

4. Fluid Level Indicator

Lock Engagement

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

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

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

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

Lock Release

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

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

1

2

3

4

51

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Steering System

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

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

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

n 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 th e 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.

n Hood and Side Panel Fasteners

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

n Recoil Rope

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

52

PRE-RIDE INSPECTIONS

Start the Engine and Check

Before starting the engine, always refer to all safety warnings pertaining
to snowmobile operation. Never engage the starter when the engine is
running. Never start the engine without checking all vehicle components
to be sure of proper operation. See Before Starting the Engine beginning
on page 48.

n Engine Stop Switch

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

n Ignition Switch

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

n Tether Switch (if equipped)

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

n Lighting

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

n Mirrors (if equipped)

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

n Operating Area

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

53

OPERATION

Starting the Engine

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

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

1. Turn the key to the ON position.

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

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

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

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

snap back into the housing. Damage may result.

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

CAUTION! To avoid injury and/o r 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 eng ine stop switch down,
restart the engine using the normal starting procedure. If the engine fails
to start using the normal procedure:

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

2. Turn the key to the OFF position.

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

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

5. Release the throttle.

6. Restart the engine using the normal starting procedure.

54

OPERATION

Break-In Period

Engine Break-In

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

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

Tip: The semi-synthetic oil will seat the rings faster than the VES Gold Plus oil.

See page 100 for the part numbers of POLARIS products.
Never mix brands of oil. Serious chemical reactions can cause injection

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

Initial Fuel Premix

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

Oil Recommendations

First Tank of Fuel: POLARIS Premium 2-Cycle Semi-Synthetic Oil
After Brea k-in: POLARIS VES Gold Plus Oil

Fuel Semi-Synthetic Oil Ratio

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

55

OPERATION

Break-In Period

Engine Break-In

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

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

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

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

Oil Injection System

Always check and fill the oil bottle when refueling. See page 59.

NOTICE: Serious engin e damage can occur without the proper lubrication.

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

Drive Belt Break-In

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

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

56

OPERATION

Track Warm-Up

WARNING! A loose track or flying debris coul d 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 snow-

mobile at the rear bumper . The track should be about 4I (10 cm) of f
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.

57

OPERATION

Fuel

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

• Always tu rn off the engine before re fueling.

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

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

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

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

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

WARNING

WARNING

58

OPERATION

Fuel Recommendation

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

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

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

Always protect painted surfaces when handling fuel.

Fuel System Deicers

If you use non-ethanol fuel (sometimes labeled “non-oxygenated”),
POLARIS recommends the regular use of isopropyl-based fuel system
deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline
to prevent damage resulting from fuel system icing. Never use deicers
or additives containing methanol. POLARIS recommends the use of
Carbon Clean Plus. See page 100 for the part numbers of POLARIS
products.

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

59

OPERATION

n Oil

Low Oil Level

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

1. Immediately stop the engine if the

low oil indicator light comes on.

2. Open the left side panel.

3. View the oil level in the oil bottle.

4. Add oil as needed before operating.

NOTICE: Operating the snowmobile without adequate engine lubrication can

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

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

“Add”

Mark

60

OPERATION

n Engine Stop Switch

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

n Throttle Safety Switch

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

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 no t 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.



61

OPERATION

Throttle Lever

WARNING! An improperly functioning throttle lever may cause erratic

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

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

1. Turn the ignition switch to OFF.

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

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

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

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

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

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

62

OPERATION

Electronic Reverse (PERCt)

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

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

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

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

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

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

WARNING

63

OPERATION

Electronic Reverse (PERCt)

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

4. Apply the throttle slowly to make sure the transmission is in
reverse.The maximum engine RPM will be 6000 when in reverse.

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

restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

engine damage, especially if the transmission 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 transmission is in for­ward.

64

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 60 for more information about the
engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES

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

65

OPERATION

Daily Storage

At the end of each ride, park the snowmobile on a level surface and su p­port it at the rear with an appropriate track stand. The track should be
suspended approximat ely 4I (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 seriou s
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) lo ng 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 someon e ride on the
towed snowmobile to operate the brake and steering when necessary.

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

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

66

MAINTENANCE

Emission Control Information

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

Emission Control Label

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

Emission Control Maintenance Requirements

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

Owner's Responsibilities

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

Non-ionizing Radiation

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

67

MAINTENANCE

POLARIS Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow
recommended regular maintenance and perform service checks as out­lined in this manual. Record maintenance and service in the Mainte­nance Log beginning on page 115.

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

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

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

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

NOTICE: Hot comp onents 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.

68

MAINTENANCE

Periodic Maintenance Interval Table

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

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

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CLUTCH

Clutch Alignment Offset
(without belt)

86 III

Drive Belt Condition 87 IIII
Clutches 86 CC C
Belt Tension -- IIII
Clutch Sheaves 86 IIII

ENGINE/COOLING

Engine Mounts -- IIII
Recoil Rope -- IIII
Cylinder Head Bolts -- III
Cylinder Base Nuts -- III
Ignition Timing BTDC -- III
VES System -- CCC I
Coolant Level 78 IIRI
Coolant Hose -- IIII
Coolant Circulation -- III
Coolant Leaks -- IIII
Spark Plugs 77 IIRI
Exhaust Pipe 81 II
Exhaust Retaining

Springs

81 IIII

69

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

BRAKES

Hose Routing -- II II
Hose Condition -- IIII
Fluid Leaks -- IIII
Brake Pads 82 IIII
Brake Disc -- IIII
Parking Brakes 50 II II
Brake System 49, 82 I
Brake Fluid 83 R

FUEL MANAGEMENT

Idle RPM -- III
Throttle Lever 61 II I I I
Oil Pump Lever

(synchronize)

-- III

Throttle Position Sensor -- III
Fuel Lines 75 IIII
Fuel Filter 75 EVERY 2000 (3200) or EVERY 2 YEARS
Oil Filter 74 RR
Oil Lines 74 III
Air Box -- III II

ELECTRICAL

Auxiliary Shut-Off
Switch

52 II I II

Throttle Safety Switch 60 III II
Ignition Switch -- III II
Taillight 52 III II
Brakelight 52 III II
Headlight 52 III II

70

MAINTENANCE

Periodic Maintenance Interval Table

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

Bolt Torque Inspection

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

Item See

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CHASSIS

Ski Toe Alignment -- III
Suspension Mounting

Bolts

-- III II

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

Fasteners

-- III II

Steering Fasteners -- III IC
Suspension Shock Oil -- R
Cooling Fins and

Shroud

-- IIII

Skags (Wear Bars) 97 II I I I
Ski Saddle/Spindle Bolts -- III I I
Drive Chain Tension 81 III II
Hood and Side Panel

Fasteners

71 II I II

Rear Wheel Idler Bolts 93 II I II
Idler Bolt Jam Nut 93 III II
Camber Alignment -- III
Handlebar Centering -- I
Tether Switch and Strap 52 III II
Track Alignment 94 III II
Track Tension 92 III II
Front Limiter Strap -- III II
Rail Slide Condition 97 I
Chaincase Oil 73 IR I RI

Item Description

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

Four (4) rear chaincase nuts

71

MAINTENANCE

Hood/Side Panel

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.

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

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

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

Strap

1/4-Turn Fasteners

72

MAINTENANCE

Lubrication

Rear Suspension

Lubricate the suspension pivot shafts with POLARIS Premium All Sea­son Grease at the intervals outlined in the Periodic Maintenance Table
beginning on page 68 and before seasonal storage. When operating in
heavy, wet snow conditions, lubricate every 500 miles (800 km).

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

X

X

X

73

MAINTENANCE

Lubrication

n Chaincase Oil

Check and change the chaincase oil at the intervals outlined in the main­tenance charts beginning on page 67. Maintain the oil level at the top of
the fill plug hole. POLARIS recommends the use of POLARIS Syn­thetic Chaincase Lube. See page 100 for the part numbers of POLARIS
products.

Oil Level

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

1. Position the vehicle on a level
surface.

2. Remove the fill plug.

3. Using a funnel, slowly add the
recommended oil until the fluid
begins to overflow.

4. Wipe the fill area with a clean
cloth.

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

Oil Change

1. Position the vehicle on a level surface.

2. Place a drain pan under the drain plug. Remove the drain plug.
Allow the oil to drain completely.

3. Clean off all metal shavings from the plug.

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

free of burrs, nicks or scratches.

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

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

6. Using a funnel, slowly add the recommended oil until the fluid
begins to overflow. Fluid capacity is 9 oz. (266 ml).

7. Wipe the fill area with a clean cloth.

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

Fill Plug

74

MAINTENANCE

Lubrication

Oil Lines

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

Oil Filter

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

TIP:The direction of the arrows indicates

the direction of flow through the fil­ter.

75

MAINTENANCE

Intake Filters

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

Fuel Pump

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

Fuel Filter/Fuel Lines

See your POLARIS dealer for replacement of the fuel filter at the inter­vals outlined in the Periodic Maintenance Table beginning on page 68.

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

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

NOTICE: Kinking th e fuel line s or using a pliers or similar tools to remove fuel

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



76

MAINTENANCE

Spark P lugs

Spark Plug Recommendations

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

Refer to your Owner's Manual Supplement for the specific spark plug to
be used in your snowmobile.

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

• Use recommended spark plugs with the proper gap.

• Use only resistor-type spark plugs.

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

• Always carry spare spark plugs.

NOTICE: Using non-recommended spark plugs can result in seriou s engin e

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

77

MAINTENANCE

Spark P lugs

Spark Plug Inspection

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

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

1. Remove the left side panel.

2. Remove the spark plug cap.

3. Using the special wrench provided in the tool pouch, rotate the
spark plug counter-clockwise to remove.

4. Reverse the procedure for spark plug installation. Torque to specifi­cation.

5. Reinstall the spark plug cap.

Spark Plug Condition

Normal Plug

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

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

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

Wet Fouled Plug

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

78

MAINTENANCE

Cooling System

Coolant

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

When adding or changing coolant, POLARIS recommends using Pre­mium 60/40 anti-freeze coolant, which is already premixed and ready to
use. Do not dilute with water . Never exceed a 60% antifreeze/40% water
mixture. See page 100 for POLARIS products.

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

n Coolant Level

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

• Coolant bottle/overflow tank

• Pressure cap

• Connecting hoses
Always maintain the coolant level at or

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

1. Stop the engine.

2. Open the right side panel.

3. View the coolant level in the coolant
bottle.

4. Add coolant as needed.

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

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

“Full Cold” Mark

79

MAINTENANCE

Cooling System

Engine Overheating

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

Illuminated Indicator

Take action to cool the engine:

• Drive in loose snow.

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

• Stop the engine and allow it to cool down.

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

Flashing Indicator

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

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

Flushing the Cooling System

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

80

MAINTENANCE

Cooling System

Bleeding the Cooling System

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

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

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

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

engine damage may result.

1. Position the vehicle so that the top of the tunnel is level. Elevate the
front of the vehicle slightly if necessary.

2. Make sure the engine is cold before continuing.

3. Remove the right side panel.

4. Fill the coolant bottle with properly mixed coolant to the maximum
mark. Do not install the pressure cap at this time.

5. Remove the bleed screw from the water outlet manifold and/or the
thermostat housing. Allow the coolant to bleed through the system
until it runs out the bleed holes. Reinstall the bleed screw into the
manifold.

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

7. Reinstall the side panel. Always ensure that the hood and side pan­els are securely in place before starting the engine.

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

9. Stop the engine and check the coolant bottle level. Add coolant as
needed. Reinstall the side panel.

10. Carefully and briefly touch the top of the tunnel cooler under the
seat. If the system is bled properly, the cooler will be warm to the
touch. If not, repeat step 8. Lift the front of the snowmobi le slig htly
to assist in the bleeding.

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

12. Carefully lower the front end of the snowmobile.

81

MAINTENANCE

Exhaust System

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

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

1. Open the side panels and remove the hood. See page 71.

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

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

4. Check for loose clamps on the pipe covers.

Drive Chain Tension

Check drive chain tension weekly and before each long trip.

1. Remove the side panels.

2. Rotate the driven clutch
counter-clockwise to move all
chain slack to the tensioner
side. Lock the brake lever
lock, or have an assistant hold
the brake lever firmly.

3. Loosen the adjuster bolt jam
nut.

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

5. Tighten the jam nut while
holding the adjuster bolt.
Torq ue to 21 ft. lbs. (28 Nm).

6. Reinstall the side panels.

7. Release the brake lever lock.

Jam

Nut

Adjuster

Bolt

82

MAINTENANCE

Brakes

Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See
page 49.

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

WARNING! Brake failure during operation can result in serious injury or death.
Properly functioning brakes are vital to your safety. Be sure the brake pads do
not drag on the disc and that brake lever travel is not excessive. Always replace
brake pads when the brake pad material becomes thinner than the backing plate

(approximately 1/16

I).

Brake Components

1. Brake Disc

2. Brake Caliper

3. Anti-rattle springs (come
with brake pad kit)

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

Excessive Lever Travel

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

1

2

4

3

83

MAINTENANCE

Brakes

Brake Fluid

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

Replace brake fluid at least every two years with POLARIS DOT 4 high
temperature brake fluid. See page 100 for the part numb ers of POLARIS
products.

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

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

NOTICE: Brake fluid will damage labels, paint and some plastics. Always wipe

up spills immediately.

84

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

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

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

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

1. Remove the brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX
marks or 1/4-5/16I (.6-.8 cm) below the lip of the reservoir open­ing. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the
flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unsc rew the bleeder
valve 3/4 of a turn to release air.

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

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a
solid stream free of air bubbles.

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

7. After bleeding is complete, refill the reservoir to the proper level.
See page 83.

8. Reinstall the gasket and cover.

85

MAINTENANCE

Lights

When servicing a halogen lamp, avoid touching the lamp with bare fin­gers. Oil from your skin leaves a residue, causing a hot spot that will
shorten the life of the lamp. If fingers do touch a lamp, clean it with
denatured alcohol.

Headlight Lamp Replacement

1. Peel back the foam shield covering the headlight assembly.

2. Remove the wire harness connector from the back of the headlight.

3. Grasp the bulb housing and turn it counter-clockwise to remove the
bulb.

4. Apply dielectric grease to the socket and install the new bulb.
Rotate the bulb 1/4 turn clockwise to secure it.

5. Reinstall the connector to the back of the headlight.

6. Secure the foam shield.

Taillight/Brake Light Replacement

The taillight assembly is not serviceable. If the light fails to operate
properly, replace the entire taillight assembly.

86

MAINTENANCE

Clutch System

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

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

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

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

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

Clutch Alignment Offset

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

87

MAINTENANCE

Clutch System

n Drive Belt Condition

Periodically check the condition and tension of the drive belt. Inspect
the belt for signs of excessive wear: frayed edges, missing cogs, cracks
and excessive looseness. Replace the belt if any of these conditions
exist. See Drive Belt Troubleshooting on page 105.

Always carry a spare drive
belt. Store the spare belt in
the belt clip located under
the left side of the hood.

For improved drive-away during extremely cold temperatures, remove
the belt and warm it to room temperature. Reinstall it before starting the
snowmobile.

88

MAINTENANCE

Clutch System

n Drive Belt Deflection

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

Place a straight edge (1) on the
belt and apply downward pressure
while measuring at point 2. This
measurement should be 1 1/4
inches (3.2 cm).

Drive Belt Adjustment

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

2. Using a 1/8-inch Allen wrench, turn the set screw inward (clock­wise) to increase the distance between the sheaves or outward
(counter-clockwise) to decrease the distance.

3. Tighten the jam nut.

1

2

89

MAINTENANCE

Clutch System

Drive Belt Removal

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

snowmobile must be stopped after forward motion to prevent damage
to components during belt removal. Rotate the driven clutch counter­clockwise 1/4 turn by hand to ensure forward engagement before
attempting to remove the belt.

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

2. Turn the ignition key off. Wait for the engine to come to a complete
stop.

3. Lock the parking brake.

4. Remove the left side panel.

5. Rotate the driven clutch counter-clockwise 1/4 turn by hand to
ensure forward engagement.

6. Locate the L-wrench in the tool kit. Install the wrench into the open
threaded hole in the outer sheave of the clutch.

7. Turn the wrench clockwise until the sheaves open far enough to
remove the belt. If the wrench does not turn readily, rotate the
driven clutch counter-clockwise an additional 1/4 turn by hand and
try again.

8. Firmly grasp the belt midway between the clutches and pull upward
and rearward to remove it.

90

MAINTENANCE

Clutch System

Drive Belt Installation

1. Drop the drive belt over the
drive clutch and pull back the
slack. The belt cord line
should be flush with, or
slightly above, the outer cir­cumference of the driven
clutch sheaves. The belt will
seat itself in the driven clutch
during the break-in period.
Adjust the belt ride-out after
the break-in period by read­justing belt deflection.

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

3. Turn the driven clutch moveable sheave clockwise while pushing
inward and forcing the belt down between the sheaves.

4. Hold the belt down between the sheaves and roll the bottom portion
over the outer clutch sheave. Work the belt to the outer edge of the
sheave.

5. Rotate the L-wrench to tighten the sheaves. Remove the wrench and
store in the tool kit.

6. Reinstall the side panel.

7. Break in the new belt. See page 55.

91

MAINTENANCE

Track Maintenance

Track Inspection

WARNING! Broken track rods can cause a rotating track to come off the

snowmobile, which could cause serious injury or death. Never operate with a
damaged track. Never rotate a damaged track under power.

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

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

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

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

Track Lubrication

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

WARNING! Operating with insufficient lubrication between the rail sli de and
track guide clips can cause track failure, loss of vehicle control and loss of
braking ability, which can result in serious injury or death. Avoid operating for
extended periods on ice and other surfaces that have little or no snow for
lubrication.

If excessive rail slide wear occurs due to poor snow conditions, addi­tional wheel kits are available. See your dealer for more information.

Track damage or failure caused by op eration on ice or under other poor
lubrication conditions will void the track warranty.



92

MAINTENANCE

Track Maintenance

WARNING! Moving parts can cut and crush body parts. When performing the

checks and adjustments recommended on the following pages, stay clear of all
moving parts. Never perform track measurement or adjustments with the engine
running.

Track Tension

Track adjustment is critical for proper handling. Always maintain cor­rect tension and alignment.

TIP:Tension adjustments should be made only after the track is warmed up and

limber.

1. Turn the engine off.

2. Lift the rear of the snowmobile and safely support it off the ground.

3. Place the recommended weight or downward pressure on the track
at the specified distance (see chart) ahead of the center of the rear
idler wheel.

4. Measure at the point where the weight is hanging.

TRACK TENSION DATA CHART

Suspension Slack Measurement Weight

Measurement

Location

PRO-RIDE

RMK

3/8"-1/2" (1.0-1.3 cm) 10 lbs.

(4.54 kg)

16" (40 cm)

ahead of rear

idler shaft

93

MAINTENANCE

Track Maintenance

Track Tension

5. Check for specified slack between the wear surface of the track clip
and the plastic slider . Refer to the T rack Tension Data Chart on page

92.

If the track needs adjustment:

6. Loosen the rear idler shaft bolt.

7. Loosen the locknuts.

8. Tighten or loosen the track adjusting screws to provide equal adjust­ment on both sides of the track.

9. Repeat the measurement on the other side of the track.

TIP:Check more frequently when the snowmobile is new.

10. Start the engine and slowly rotate the track at least five revolutions.
Let the track come to a stop (do not apply brakes).

11. Check track alignment (see page 94) and adjust as necessary.

12. Tighten the locknuts.

13. Tighten the idler shaft bolts.

14. (

n) Torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).

Slack Measurement

Lock Nut

Adjusting Screw

Track

10 lbs. (4.54 kg)

Shaft

Bolt

16

I(40 cm)

94

MAINTENANCE

Track Maintenance

n Track Alignment

Periodically check that the track is centered and running evenly on the
slide rails. Misalignment will cause excessive wear to the track and slide
rail.

1. Safely support the rear of the snowmobile with the track off the
ground.

2. Start the engine and apply a small amount of throttle until the track
turns slowly at least five complete revolutions. Stop the engine and
let the track come to a stop (do not apply brakes).

3. Inspect track alignment by
looking through the track
window to make sure the
rails (X) are evenly spaced
on each side. If the track
runs to the left, loosen the
idler shaft bolts, then
loosen the left locknut and
tighten the left adjusting
bolt. If the track runs to the
right, loosen the idler shaft
bolts, then loosen the right
locknut and tighten the
right adjusting bolt.

4. After adjustments are com­plete, tighten the locknuts
and torque idler shaft bolts
to 35 ft. lbs. (47.5 Nm).

5. Repeat steps 2 and 3 to verify proper alignment.

X

95

MAINTENANCE

Steering System

Steering Inspection

Each week, or before a long ride, check all steering system fasteners and
tighten if necessary.

X

X

X

X

96

MAINTENANCE

Steering System

Ski Alignment

WARNING! Improper ski alignment or adjustment may cause loss of steering

control, resulting in serious injury or death. Do not attempt to change the ski
alignment or camber adjustment. See your POLARIS dealer.

With the handlebars in a straight ahead position, and with vehicle
weight compressing the suspension, measure from the straight edge of
the skis at the center of the ski mounting bolt. The measurement
between the skis at point X should be 1/8I to 1/4I (3-6 mm) greater
than the measurement at point Y.

TIP:If the skis are misaligned, we recommend that your dealer correct the align-

ment, since camber adjus tment may also be affected.

10I

X

10I

Y