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800 RMK 800 PRO-RMK 800 RMK ASSAULT

1. Wind Actual Thermometer Reading F Spoed 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 MPH Equivalent Temperature _F Calm 40 35 30 25 20 15 10 5 O 5 10 15 20 25 30 35 40 45 5 36 31 25 19 13 7 1 5 11 16 22 28 34 40 46 52 57 63 10 34 27 21 15 4 1 10 16 22 28 35 41 47 53 59 66 72 9 15 32 25 19 13 6 O 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 3 1 0 25 29 23 16 4 11 17 24 31 37 44 51 58 64 71 78 84 30 28 22 15 5 12 19 26 33 39 46 53 60 67 73 80 87 35 28 21 14 7 14 21 27 34 41 48 55 62 69 76 82 89 40 27 20 13 15 22 29 36 43 50 57 64 71 78 84 91 45 26 19 12 2 9 16 23 30 37 44 51 58 65 72 79 86 93 50 26 19 12 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 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 gt gt 30 min 10
2. ID while measuring at point 2 This wey J measurement should be 1 1 4 ae 4 inches 3 2 intus 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 clock wise to increase the distance between the sheaves or outward counter clockwise to decrease the distance 3 Tighten the jam nut 92 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 counter clockwise 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 u
3. For more information about avalanche training and avalanche condi tions contact local law enforcement in your area or visit the American and Canadian online avalanche centers at www avalanche org 15 SAFETY Operator Safety Ice and Snow Build up WARNING Ice and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Driving on Slippery Surfaces WARNING Never attempt an abrupt change of direction when operating on slippery surfaces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces steering and braking control which may result in loss of control and serious injury or death Slow down and use extra caution when operating on slippery surfaces Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is a requirement for operation of your snowmobile NOTICE Driving in too little snow will result in excessive wear and damage to the slide rail track and or engine WARNING Inadequate cooling and lubrication will lead to overheating of the slide ra
4. WAI MERE ANE PRO RMK ASSAULT 27 FEATURES Storage Bag Tool Kit Storage Bag A storage bag and tool kit is located under the left side panel between the oil bottle and con sole 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 down ward 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 snowmo bile 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 28 FEATURES Fuel Resistor This snowmobile is equipped with a feature that allows the engine con troller to select the proper operating software based on the type of fuel being used See pages 59 60 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 doub
5. The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly The lock will return to the unlocked position WARNING If the parking brake lever lock is partially or entirely engaged while riding the brakes may overheat resulting in brake damage In extreme cases it could cause a fire which could result in serious injury or death Always ensure that the lever lock is completely disengaged before operating the snowmobile 52 PRE RIDE INSPECTIONS Before Starting the Engine Steering System WARNING Ice and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Track Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty WARNING Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss
6. PMS 419 IMPORTANT NOTICE TO OWNER Modifications to this snowmobile are not recommended and may result in voided warranty coverage Please read the warranty section of this manual carefully The Way Out 800 800 PRO RMKC LJ 800 RMK ASSAULT Snowmobile Owner s Manual for Maintenance and Safety A 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 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 100 RECYCLED The text is printed on 10096 recycled with 4096 post consumer waste PCW POLARIS The Way Out PMS 419 For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922844 Rev 01 Printed in USA DOLI LLLI LI LII 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 introduc tions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products
7. 13 Tighten the idler shaft bolts 14 n Torque idler shaft bolts to 35 ft 165 47 5 Nm 97 MAINTENANCE Track Maintenance 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 H 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 7 right adjusting bolt v 4 After adjustments are com plete tighten the locknuts and torque idler shaft bolts to 35 ft Ibs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment 98 MAINTENANCE Steering System Steering Inspection Each week or before a long ride check all steering system fasteners and tighten if necessary 99 MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury
8. 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 gt gt 30 min 10 min 5 min 20 SAFETY Safety Labels and Locations Warning 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 instruc tions 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 pro vided 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 1
9. 44 THE PERFECT FIT Suspension Adjustments Shock Compression Damping RMK ASSAULT RMK The primary adjustment for overall vehicle balance is RTSS preload Perform this adjustment first See page 42 After adjusting RTSS pre load to your satisfaction compression damping adjustments can be made to control ride quality and bottoming resistance 800 RMK Damping Make the adjustments in half turn incre ments then test ride To stop bottoming turn the damping screw clockwise one half turn then test ride Repeat the adjustment until bottom ing stops and the desired ride quality is achieved ASSAULT RMK Damping Compression damping can be adjusted at the front suspension and at the rear track shock Make adjustments in 2 click incre ments then test ride When adjusting the front suspension always adjust both clickers equally To stop bottoming of the front or rear sus pension 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 45 THE PERFECT FIT Suspension Adjustments Independent Front Suspension and Front Track Shock Spring Preload RMK PRO RMK Factory settings combin
10. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited war ranty for your vehicle POLARIS Industries Inc warrants that at the time it is first pur chased this emissions certified vehicle is designed built and equipped so it conforms with applicable U S Environmental Protection Agency emission regulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and continues for a period of 200 hours of engine operation 4000 kilo meters 2485 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehi cle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Ignition system Fuelsystem Exhaust gas recirculation systems The following parts are also consider
11. 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 refer enced pages Look for a checkmark n on the referenced pages to locate the pre ride inspection items Item See Page Drive Belt Condition 91 Steering System 53 Recoil Rope 53 Coolant Level 81 Chaincase Oil Level 75 Injection Oil Level 61 Parking Brake Lock Brake Lever Brake System 51 52 86 Auxiliary Shut Off Switch Engine Stop Switch 54 Ignition Switch 54 Headlight Taillight Brakelight 54 Suspension Mounting Bolts 49 Skags Wear Bars 101 Ski Saddle and Spindle Bolts 49 Hood and Side Panel Fasteners 73 Throttle Lever Safety Switch 62 63 Rear Wheel Idler Bolts 97 Tether Switch Strap if equipped 54 Track Alignment Condition 53 98 Rail Slide Condition 101 48 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 follow ing items on a weekly basis or before any long trip Item See Page Check suspension mounting bolts for tightness z Check rear idler wheel bolts for tightness 97 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter st
12. corrosion or defects in parts components or the snowmobile due to fire explosions or any other cause beyond POLARIS control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the snowmobile The exclusive remedy for breach of this warranty shall be at POLARIS exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARIS ING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CON SEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 112 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR R
13. e Snowmobiles All terrain vehicles ATVs e 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 pro duced 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 ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS THE WAY OUT RMK and ASSAULT 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 const
14. the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS Initial dealer preparation and setup of your snowmobile is very important in ensuring trouble free operation Purchasing a snowmobile in the crate or without proper dealer setup will void your warranty coverage Warranty Coverage and Exclusions Limitations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for pur poses other than for which it was manufactured The warranty does not cover any dam ages that occur during trailer transit or as a result of unauthorized service or parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material
15. u 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 pan els 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 snowmobile slightly 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 83 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 sy
16. BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehi cle
17. Center Odometer Engine Hour Display Area This area displays the odometer Trip 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 vehi cle 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 manufac ture To change the display press and release the SELECT button or the SET switch until the desired item is displayed To reset a trip meter press and hold the SELECT button or the SET switch until the meter resets to zero Playback Function The playback function allows the rider to record and play back engine speed vehicle speed and throttle position sensor information for up to three minutes 1 To begin recording simultaneously press and hold the MODE and SELECT buttons on the instrument cluster for three seconds The playback indicator will flash while the instrument cluster is record ing 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 37 FEATURES Instrument Cluster Rider Information Center Standard Metric Display The odometer and temperature disp
18. Condition SPN 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 Voltage Too High 167 3 Potential DC Chassis Voltage Voltage Too Low 4 Exhaust Temperature Sensor Voltage Too High 173 3 Voltage Too Low 4 40 Instrument Cluster FEATURES 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 B4 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 1352 0 Correction Limit Reached Knock Above Critical Level 16 Knock Level Cylind
19. Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your vehicle was purchased War ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If You Move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Vehicles importa tion rules vary considerably from country to country You may be
20. MODE SELECT Button Button The instrument cluster contains indicator lights and the rider infor mation center The information MODE ter 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 Mode Set Switch the lens and other plastic sur RMK faces Do not use alcohol to clean the instrument cluster Immediately clean off any Mode Set Switch gasoline that splashes on the PRO RMK ASSAULT instrument cluster 32 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 over heating The operator should take action to cool the engine See page 82 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 recom mended oil before further operation See page 61 High Beam Indicator The high beam indicator illuminates when the lights are set to high beam Parking B
21. Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine POLARIS Customer Service United States 1 888 704 5290 Canada 1 204 925 7100 110 WARRANTY Service and Warranty Information POLARIS Anti Theft System The POLARIS anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines Administration 1 POLARIS snowmobile owner reports theft A In addition to notifying the proper law enforcement officials the owner must call POLARIS Customer Service B Owners must provide their name address telephone number and the model and serial number of stolen machines 2 POLARIS warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 POLARIS warranty will aid in notifying the proper owner when a unit is recovered 111 WARRANTY Limited Warranty POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 provides ONE YEAR LIMITED WARRANTY on all components of the POLARIS snowmobile against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty The warranty begins on the date of purchase This warranty is transferable to another consumer dur ing the warranty period through a POLARIS dealer Registration At the time of sale
22. accessories specifically approved for this model by POLARIS Do not place clothing bags or cargo on tunnel Do not cover this label 23 SAFETY Safety Labels and Locations Operation Warning The operation warning label is also located on the console Operation Warning WARNING To avoid serious injury or death read and understand all warnings and the Owner s Manual before operation If manual is missing con tact 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 vehi cle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements continued on next page 24 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
23. end of the skag 4 Remove the rear end of the skag Skag 5 Reverse the steps to install a skag Rail Slide Wear For ease of inspection all A 7 POLARIS rail slides have a wear limit indicator groove to indicate the min Minimum Thickness imum permissible slide thickness Replace the rail slides if they are worn to the top of the groove at any point along their length Failure to do so may result Replace when in permanent damage to the track or rails worn to top of groove 101 MAINTENANCE Fall Tune Up For maximum performance arrange for a fall service tune up with your POLARIS dealer His experienced and trained service technician will keep your snowmobile in peak operating condition Transporting the Snowmobile Whenever the snowmobile is transported 1 Be sure the fuel cap and oil cap are installed correctly 2 Tiethe snowmobile to the transporting unit securely using suitable straps 3 Remove the ignition key to prevent loss Extended Storage Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components See page 104 for the part numbers of POLARIS products Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood side panels chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously
24. fill plug hole POLARIS recommends the use of POLARIS Syn thetic Chaincase Lube See page 104 for the part numbers of POLARIS products Oil Level Fill Plug 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 Ibs 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 Ibs 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 Wipe the fill area with a clean cloth 8 Reinstall the fill plug Torque to 6 10 ft 165 8 13 Nm 75 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel This should take approximately two pumps Do not use more than four pumps 76 MAINTENANCE Intake Filters The intake foam filters limit snow ing
25. immediately fol lowing the engine hour display TIP When the diagnostic mode is displayed the check engine warning indicator will begin to flash 3 Asetoftwo 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 but ton 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 39 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
26. of control resulting in serious injury or death Always inspect the track for damage before using the vehicle WARNING Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions Hood and Side Panel Fasteners The hood and side panels of the snowmobile protect the operator from moving parts Never operate a snowmobile with the hood or side panels open or removed Always ensure that the hood and side panels are securely in place before starting the engine Seat Latches If your snowmobile is equipped with a removable seat ensure that the seat is properly installed and securely latched before each use of the snowmobile Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear is found see your POLARIS dealer for replacement 53 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
27. 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 A WARNING The engine exhaust from this product contains chemicals known to cause can cer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 59 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 1096 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 104 for the part numbers of POLARIS p
28. 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 adjustment may also be affected 100 MAINTENANCE Steering System Ski Skags WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommended skags If you install longer or more aggressive carbide skags than the original equipment it may also be necessary to add track studs to maintain proper vehicle control while turning on hard packed snow or ice Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter TIP Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement 1 Raise and support the front of the snowmobile so the skis are approximately 61 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front
29. procedures that must be performed before riding Operation 222 2 2924 ERREE EE REY ER 55 This section explains proper engine break in operation of features and general operating procedures Maintenance 68 This section defines your role and your dealer s role in your snowmo bile s regular maintenance POLARIS Products 104 105 Warranty 110 Maintenance Log 119 Index us E ERRECE ITE 122 INTRODUCTION Important Notes for Owners and Drivers After reading this manual store it in the snowmobile for convenient ref erence It should remain with the snowmobile when the snowmobile is sold Some of the illustrations and photos used in this manual are general rep resentations 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
30. 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 NO STEP 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 igni tion 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
31. stopping A passenger reduces your ability to control the vehicle When operating on hard packed snow ice or when crossing roads steering and braking ability are greatly reduced Reduce speed and allow extra space to turn or stop To maintain vehicle control on ice or hard packed surfaces you should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for long periods Do not leave brake engaged for more than five minutes Before starting engine check throttle brake and steering for proper operation Make sure hood and side panels are latched Be seated and in position to control the vehicle Cil injection system Use unmixed fuel only Check oil level when refueling 25 FEATURES 9 Bo 2 1 Nosepan 8 Operator Seat 2 Skis 9 Taillight 3 Front Bumper 10 Rear Bumper 4 Hood 11 Snow Flap 5 Headlight 12 Suspension 6 Windshield accessory 13 Track 7 Handlebar 14 Side Panel 15 Side Panel Fasteners 26 Thumbwarmer Switch Electronic Reverse Button Mode Switch 12 18 9 Headlight Dimmer Switch FEATURES Fuel Filler Cap Instrument Cluster Ignition Switch Engine Stop Switch Throttle Control Recoil Starter Handle Brake Lever Parking Brake Lock Handlebar Grip Warmer Switch
32. suspension adjustment and set up information transfer when beginning on page 42 climbing Machine darts from side to side Check ski alignment see page 100 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Front end pushes Check for worn skags Check for binding front suspension shafts and steering components grease all pivot points elevate front of snow mobile Increase IFS preload if equipped see page 46 Steering is heavy Make sure spindles and all steering components turn freely Check ski alignment see page 100 Check skags and skis for damage 108 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear Burn Diagnosis Causes Solutions Driving at low RPM Drive at higher RPMs Gear the machine down Check belt deflection Insufficient warm up Warm the engine at least five minutes Take the drive belt off the snowmobile in extremely cold weather and warm it up Break snowmobile loose from the snow Towing at low RPM Do not tow in deep snow Use fast aggressive throttle to engage clutch Riding with high RPM Lower the gear ratio Reduce RPM Avoid riding in and slow speed 8000 high ambient temperatures Check for snow ingestion RPM 10 MPH 16 km h Ice and snow build up between track and tunnel Warm the engine at least five mi
33. the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer Odometer Engine Hour Display This area displays the odometer Trip A Trip B and engine hours To change the display see page 37 Battery Power This indicator illuminates when battery power is low Playback Icon The playback function allows the rider to record and play back engine speed vehicle speed and throttle position sen sor information for up to three minutes The playback icon flashes while recording See page 37 35 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 Tochange which item displays first make sure the information dis play area is set to display either engine speed or vehicle speed 2 Press and hold the mode button on the instrument cluster or the mode switch on the left handlebar for three seconds Information Display Area This area displays either engine speed or vehicle speed whichever is not displayed in the speed display engine temperature and maximum vehicle speed To change the display press and release the MODE but ton or the MODE switch until the desired item is displayed 36 FEATURES Instrument Cluster Rider Information
34. 27 6 cm 9 7 8 25 cm Installed Length Measurement 42 THE PERFECT FIT Suspension Adjustments For riders who weigh 160 220 Ibs 73 100 kg test ride at factory settings then make fine tuning adjustments See page 44 For riders outside the 160 220 Ibs 73 100 kg weight range adjust the factory set preload to the following installed lengths as a starting point then test ride before making fine tuning adjustments Do not exceed the minimum and maximum installed length requirements See page 42 TIP If adjustments to the factory installed springs are not sufficient for riders over 300 Ibs 136 kg optional heavy springs are available Please see your POLARIS dealer Initial RTSS Preload Settings Measure spring length with suspension off the ground Rider Weight Model Installed Length For Factory Installed Springs Under 160 lbs Under 73 kg RMK PRO RMK 10 3 4 27 3cm ASSAULT RMK 10 7 8 27 6 cm 160 220 Ibs 73 100 kg RMK ASSAULT 10 1 4 26 cm RMK PRO RMK 10 3 8 26 4 cm 220 280 Ibs 100 127kg RMK PRO RMK 10 1 8 25 7 cm ASSAULTRMK 10 25 4cm 280 340 Ibs 127 154 kg RMK PRO RMK 93 4 24 8 cm ASSAULT RMK 91 2 24 1 cm Factory Setting For Optional 250 Pound Heavy Springs 250 300 Ibs 113 136 kg ALL 10 1 8 25 7 cm 300 350 Ibs 136 159 kg ALL 10 25 4 cm 43 THE PERFECT FIT Suspension Adj
35. 3 PSI 21 SAFETY Safety Labels and Locations No Passenger Warning Reverse Warning No Passenger Warning Snowmobiles designed for a single rider only have the NO PASSEN GER warning label on the lower left side of the console WARNING This vehicle is designed for operator only NO PASSENGER Reverse Warning The reverse warning label is located on the console either beside the steering post or below the windshield WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Machine stopped and engine at idle push yellow button on LH con trol to reverse Flashing light on dash indicates reverse operation Push button again to return to forward 22 SAFETY Safety Labels and Locations Track Warning Hot Surface Track The track warning label is on the Warning Warning 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
36. 70505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carb and Throttle Body Cleaner 2878018 Shock Thread Spray Lubricant 104 TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two cycle engine repair see your dealer if technical problems arise Problem Probable Cause Solution Erratic engine oper ating RPM during acceleration or load variations Drive clutch binding SEE YOUR DEALER Driven clutch mal function SEE YOUR DEALER Harsh drive clutch engagement Drive belt worn or too narrow Replace the drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for appli cation Replace the drive belt Clutch alignment out of spec Engine mount bro ken or loose SEE YOUR DEALER Inspect and replace SEE YOUR DEALER Machine fails to move Clutch jammed Check for twisted belt or broken spring SEE YOUR DEALER Track jammed Foreign object may be caught or the rail slide melted to the track clips due to lack of lubrication Track may be iced up or frozen to the ground Chaincase sprocket or chain jammed or broken Chain is loose or broken or chain tightener is loose SEE YOUR DEALER 105 TROUBLESHOOTING Engine Troubleshooting Problem Proba
37. 87 Components 86 Inspection 86 Lever 86 System Bleeding 88 Break In 56 57 C Chaincase 75 Cleaning Preservation for Storage 102 Clutch Alignment Offset 90 Clutch 18 Clutch System 90 94 Clutch Warning 21 Clutch Drive System Care Storage 103 Cold Weather Drive Away 18 Controls Linkage Care Storage 103 Coolant 81 Coolant Level 81 Cooling System 81 83 Cooling System Bleeding 83 Cooling System Flushing 82 Customer 110 D Detonation Elimination Technology 30 31 Diagnostic Display Codes 40 41 Diagnostic Display Mode 39 Disabled Operators 12 Display Standard Metric 38 122 D Drive Belt tie etn 18 Drive Belt Break In 57 Drive Belt Adjustment 92 Drive Belt Condition 91 Drive Belt Deflection 92 Drive Belt Installation 94 Drive Belt Removal 93 Drive Chain Tension 85 Driver Awareness 14 Driveshaft Bearing Lubrication 76 Driving Downhill 17 Driving in Hilly Terrain 17 Driving on Slippery Surfaces 16 Driving Responsibl
38. ANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law How to Obtain Warranty Service If your snowmobile requires warranty service you must take it to a POLARIS dealer authorized to repair POLARIS snowmobiles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility POLARIS recommends that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at POLARIS if additional assistance is needed This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of POLARIS engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 113 WARRANTY Conditions and Exclusions In order to qualify for warranty the product must have been properly set up and tested by a POLARIS Dealer if app
39. LARIS 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 snow mobile Cil Injection System Always check and fill the oil bottle when refueling See page 61 NOTICE Serious engine damage can occur without the proper lubrication Check the oil bottle level often during the first tank of fuel If the oil level doesn t go down contact your dealer immediately Drive Belt Break In The break in period for a new drive belt is 30 miles 48 km During this time vary the throttle position under 50 and limit full throttle use Always take time to warm up the belt and driveline prior to operating the snowmobile Free the track and skis from the ground before engag ing throttle 57 OPERATION Track Warm Up WARNING A loose track or flying debris could cause serious injury or death Stand clear of the front of the snowmobile and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throttle during warm up or when the track is free hanging Use a stable rear support WARNING Use of traction products such as studs ice growsers etc will increase the possibility of track damage and or failure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper w
40. PECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine Brake Lever Travel Squeeze the brake lever It should move no closer to the handgrip than L 21 1 3 cm 1 21 1 3 em A smaller distance indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 88 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 87 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always have the brakes Serviced at the first sign of sponginess 51 PRE RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock gt 3 4 only when you want the snow mobile to remain stationary for example when parked on an incline for a period of five min utes 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 for ward 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
41. POLARIS also recommends that you use only Pure POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the POLARIS Warranty Department at 1 888 704 5290 118 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km 119 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS KM 120 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 121 INDEX A Accessories 28 Air Pollution 6 1 15 B Belt 57 Brake Lever Travel Inspection 51 Brakelight Replacement 89 Brak 2 ee eh 51 86 88 Brake Fluid
42. See Before Starting the Engine beginning on page 50 Engine Stop Switch Check the auxiliary shut off switch for proper operation Push the switch down to stop the engine Pull it up to allow restarting Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF Tether Switch if equipped If your snowmobile has a tether switch remove the tether from the switch to make sure the engine stops immediately Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating Mirrors if equipped Adjust the mirrors so they can be used to their full advantage Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile 54 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 Ifequipped with electric start turn the key to START to crank the engine Release the key to the ON position when the engine starts 4 Ifnotequipped 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 exte
43. a carburetor throttle system malfunction immediately push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer Test the throttle safety switch system daily before operation 1 Sit on the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pres sure 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 62 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 Ifthe throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 Ifthe engine doesn t start take the snowmobile to an authorized POLARIS dealer for service Excessive freeplay in the throttle cable may cause t
44. akes 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 87 8 Reinstall the gasket and cover 88 MAINTENANCE Lights When servicing a halogen lamp avoid touching the lamp with bare fin gers 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 2 3 4 5 6 Peel back the foam shield covering the headlight assembly Remove the wire harness connector from the back of the headlight Grasp the bulb housing and turn it counter clockwise to remove the bulb Apply dielectric grease to the socket and install the new bulb Rotate the bulb 1 4 turn clockwise to secure it Reinstall the connector to the back of the headlight 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 89 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 t
45. and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses sponsored by local or state organizations INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education cam paign We encourage state and provincial governments across the snow belt 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 pro tect 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 stan dards 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 manufac turing quieter machines we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly Air Poll
46. ant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation 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 RMK 800 PRO RMK 800 RMK ASSAULT Owner s Manual P N 9922844 2 TABLE OF CONTENTS Introduction 5 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner s manual Safety enkKEREREBBRRISPRRE Rd 8 This section describes safe vehicle operation and identifies warning labels and their locations Features on 222g xa EEEEEMDBENEAA T ees 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 experi ence Pre Ride Inspections 48 This section explains
47. arm 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 off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions TIP It will take longer to warm up the track sufficiently during colder outdoor temperatures 4 Release the throttle apply the brakes shut off the engine and lower the snowmobile to the ground 5 Grasp the skis by their front loops and move them from side to side to loosen snow and ice Slide Rail and Track Cooling NOTICE Inadequate cooling and lubrication will lead to overheating of the slide rail and track resulting in premature wear and failure Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating on ice hard packed surfaces or roads 58 OPERATION Fuel AWARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel outdoors or in a well ventilated area Always turn off the engine before refueling Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored If gasoline spills
48. ble Cause Solution Noise in drive Broken drive clutch SEE YOUR DEALER system components Bearing failure SEE YOUR DEALER chaincase jackshaft or front drive shaft Drive belt surface nspect and replace as needed flat spots Drive chain loose nspect and adjust or replace Drive chain worn SEE YOUR DEALER sprocket teeth bro ken Poor low RPM Worn drive belt nspect and replace as needed performance Excessive belt sheave clearance SEE YOUR DEALER Sticky clutch SEE YOUR DEALER Poor fuel quality Use 87 91 octane fuel or higher Engine doesn t turn Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fuel supply broken parts or improper cooling Hydrostatic lock Fuel may have entered the crankcase while the vehicle was standing or being transported SEE YOUR DEALER to correct the cause Drain plug s are located on the lower crankcase for emergency draining 106 Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails to start Faulty ignition TROUBLESHOOTING Install new spark plug s If engine still fails to start check for spark If there s no spark SEE YOUR DEALER No fuel to engine Make sure the fuel valve is on Make sure tank contains fuel Ice may be in the fuel line filter or pump Add isopropyl alcohol to the fuel system SEE YOUR DEALER Poor engin
49. e com pression This indicates a major engine prob lem that must be repaired before operating SEE YOUR DEALER backfires Engine lacks power Fouled or defective Replace the plug s spark plug s Fuel filter loss of SEE YOUR DEALER high RPM power Plugged fuel filter or SEE YOUR DEALER tank pick up sock Incorrect clutching SEE YOUR DEALER Engine continually Faulty plug s Change plug s Fuel System Dirt or ice may be in the fuel system deicer should be added to non etha nol fuel at all times for assurance against fuel line icing tank pick up sock Incorrect throttle SEE YOUR DEALER freeplay or faulty switch Engine requires Poor fuel Replace with fresh winter fuel th 1 pulls to start Not enough fuel get SEE YOUR DEALER ting to engine Plugged fuel filter or SEE YOUR DEALER 107 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension Refer to the suspension adjustment and set up information bottoms too easily beginning on page 42 Revalve rear track shock see your dealer Rides too stiff in rear Refer to the suspension adjustment and set up information beginning on page 42 Check for binding suspension shafts and grease all pivot points Too much weight Refer to the suspension adjustment and set up information transfer when beginning on page 42 climbing Too little weight Refer to the
50. e 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 82 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION Steam and hot liquids will cause burns to your skin Never bleed the cooling system or remove the pressure cap when the engine is warm or hot Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part NOTICE If coolant flow becomes restricted or plugged coolant loss air lock or engine damage may result 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
51. e the responsibility of the regis tered 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 adjust ments 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 comfort able performing these tasks yourself contact an authorized POLARIS dealer for service NOTICE Hot components can cause damage to plastic Always make sure the exhaust system and engine have cooled before tipping the snowmo bile on its side for service or inspection 69 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions You may need to increase frequency based on riding conditions When inspection reveals the need for replacement parts always use genuine POLARIS parts available from your POLARIS dealer Item See Frequency Page iso mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CLUTCH Clutch Alignment Offset 90 1 1 1 without belt Drive Belt Condition 91 l 1 1 Clutches 90 C Cc C Belt Tension s l 1 l Clutch Sheaves 90 1 1 1 ENGINE COOLING Engine Mounts 1 l Recoil Rope l 1 1 1 Cy
52. ect tension and alignment TRACK TENSION DATA CHART Suspension Slack Measurement Weight pe ae PRO RIDE 3 8 1 2 1 0 1 3 cm 10 Ibs 16 40 cm RMK 4 54 kg ahead of rear idler shaft 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 96 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 Track Tension Data Chart on page 96 If the track needs adjustment 6 Loosen the rear idler shaft bolt 7 Loosen the locknuts Adjusting Screw Soi Lock Nut ack Measurement rack 16040 cm 10 Ibs 4 54 kg 8 Tighten or loosen the track adjusting screws to provide equal adjust ment 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 98 and adjust as necessary 12 Tighten the locknuts
53. ed emission related components for exhaust emis sions e Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emis sions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables FuelLine Control Linkages Fuel Line Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 117 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of POLARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR POSE ALL IMPLIED WARRANTIES INCLUDING
54. ed to the fuel and oil injection systems will provide the necessary engine lubrication Oil Recommendations First Tank of Fuel POLARIS Premium 2 Cycle Semi Synthetic Oil After Break in POLARIS VES Gold Plus Oil Tip The semi synthetic oil will seat the rings faster than the VES Gold Plus oil See page 104 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 Fuel Semi Synthetic Oil Ratio Each 5 gal 19 I 16 oz 473 ml 40 1 56 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 fit ting 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 PO
55. ed with user adjustments to the rear track shock spring should be all that s necessary to provide the best riding experi ence for most riders The primary adjustment for overall vehicle balance is RTSS preload Perform this adjustment first See page 42 After adjusting the 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 front 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 46 THE PERFECT FIT Handlebar Adjustments Loosen top bolts to adjust handlebar angle se us m qm a 11 l Loosen bottom bolts to adjust handlebar position if equipped Handlebar Position if equipped 1 Loosen the four bolts on the bottom of the adjuster block If neces sary pry the blocks apart with a screwdriver 2 Adjust the handlebar forward or rearward to the desired position 3 Tighten the bolts Handlebar Angle 1 Loosen the four bolts on the top of the adjuster block If necessary pry the blocks apart with a screwdriver 2 Adjust the handlebar forward or rearward to the desired angle 3 Tighten the bolts 47 PRE RIDE INSPECTIONS
56. ence Before allowing someone else to use your snowmobile know the extent of their operating skills Check to see if they ve taken a snow mobile safety course and have an operator s certificate For their pro tection 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 pro tection 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 defen sively to avoid accidents Remove the key from the ignition when you leave the snowmobile unattended 19 SAFETY Operator Safety Windchill Temperature Charts The following information is provided to help you determine when tem peratures become dangerous for riding WINDCHILL CHART F
57. er 2 PTO Maximum Detonation 1353 0 Correction Limit Reached Knock Above Critical Level 16 Sensor Supply Voltage 1 TPS Voltage Too Low 3509 4 TMAP Sensor Power Sensor Supply Voltage 2 Ground Voltage Too Low 3510 4 Speed Sensor ECU Output Supply Voltage 2 Injec Voltage Too High 3598 3 tion Supply PWR 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 41 THE PERFECT FIT Suspension Adjustments Factory settings combined with user adjustments to the rear track shock spring RTSS should be all that s necessary to provide the best riding experience for most riders The primary adjustment for overall vehicle balance is RTSS preload Perform this adjustment first NOTICE Never adjust spring preload to an installed length longer than the maximum or shorter than the minimum lengths in the following chart Damage to the suspension could result Spring Type Maximum Minimum Installed Installed Length Length RMK Factory Spring 10 3 4 27 3 cm 9 5 8 24 5 cm PRO RMK Factory Spring 11 28 cm 9 3 4 24 8 cm ASSAULT RMK Factory Spring 11 28 cm 9 3 8 23 8 cm 250 Optional Heavy Spring 10 7 8
58. estion into the intake system When operating in loose powder snow check the foam fil ters periodically to remove any accumula tion of snow Fuel Pump 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 inter vals outlined in the Periodic Maintenance Table beginning on page 70 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 dete rioration from weather and fuel compounds may occur Replace worn or damaged fuel lines promptly NOTICE Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly 77 MAINTENANCE Spark Plugs Spark Plug Recommendations A new engine can cause temporary spark plug fouling due to the preser vative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization Refer to your Owner s Ma
59. g 22 Rider 13 Rider Information Center 34 41 Riding Apparel 11 Riding Position 10 S Safety Labels 21 24 Safety Symbols 8 Shock Compression Damping 45 Side Panel Access 73 Side Panel Fasteners 53 Signal 8 Ski 100 Ski 8 101 Slide Rail and Track Cooling 58 Snow Conditions 16 Spark Plug Condition 79 Spark Plug Inspection 79 Spark Plug Recommendations 78 Spark Plugs 78 79 Peed s d rr y 13 Speed Display 36 Spring 1 46 Standard Metric Display 38 Starting the Engine 55 Starting the Engine Restarting 55 Steering Inspection 99 Steering System 99 101 Steering System Inspection 53 Stopping Emergency 66 Storage Bag Under Seat 28 Storage Procedures 102 103 Storage Daily 67 Storage 8 28 Survival Preparation 12 124 S Suspension Adjustments 42 46 Suspension Inspection Pre Ride 49 Suspension Lubrication Rear 74 Suspension Set Up Fine Tuning 44 Switches Engine Stop Switch 62 Mode Select Butt
60. he 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 63 OPERATION Electronic Reverse PERC AWARNING 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 trans mission 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 64 OPERATION Electronic Reverse PERC Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure
61. he snowmobile until repairs have been made 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 lubri cate clutch bushings Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum perfor mance See your dealer for service and adjustments A special tool is required to check for proper alignment 90 MAINTENANCE Clutch System 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 109 Always carry a spare drive belt Store the spare belt in the left side of the hood i 3 the belt clip located under For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile 91 MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position oam d Place a straight edge 1 on the f NN ve belt and apply downward pressure y f
62. hragm may be restricted altering brake function NOTICE Brake fluid will damage labels paint and some plastics Always wipe up spills immediately 87 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action Bleed the system before operating the snowmobile WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Never operate the vehicle with a spongy feeling brake lever During the bleeding procedure keep the brake handle as level as possi ble 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 Fillthe 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 unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles WARNING Overfilling the master cylinder leaves no room for fluid expansion and may cause the br
63. il and track causing premature wear damage and failure which can result in serious injury Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating for prolonged periods on ice hard packed surfaces or roads Operating in Deep Snow If the snowmobile becomes stuck in snow clear the running board area of snow then step down the snow in front of the snowmobile so that when the throttle is opened the snowmobile will be able to climb up and over the snow 16 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 terrai
64. l is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 161 Brake Components 1 4 3 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thickness is less than 1 161 1 5 mm 4 Anti rattle springs come with brake pad kit Excessive Lever Travel Hydraulic brakes are self adjust ing but if excessive brake pad clearance develops bring the snowmobile to an authorized POLARIS dealer for inspection and adjustment 86 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 104 for the part numbers of POLARIS products WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury WARNING Keep the master cylinder cover free of dirt and debris The vent slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diap
65. lays 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 38 FEATURES Instrument Cluster Rider Information Center Diagnostic Display Mode The diagnostic display mode is for informational purposes only Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check engine warning indicator is illuminated 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
66. le Item See Frequency Page iso mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CHASSIS Ski Toe Alignment 1 1 Suspension Mounting 1 1 1 1 1 Bolts Bolt Torques See your dealer every 1000 mi 1600 km for inspection Rear Suspension 1 1 1 1 1 Fasteners Steering Fasteners 1 1 1 1 Suspension Shock Oil R Cooling Fins and 1 Shroud Drive Shaft Bearing 76 Skags Wear Bars 101 Ski Saddle Spindle Bolts Drive Chain Tension 85 r Hood and Side Panel 73 Fasteners Rear Wheel Idler Bolts 97 1 l 1 1 1 Idler Bolt Jam Nut 97 1 1 Camber Alignment 1 1 1 Handlebar Centering Tether Switch and Strap 54 1 1 1 1 Track Alignment 98 l l 96 1 l 1 1 Front Limiter Strap 1 1 Rail Slide Condition 101 1 Chaincase Oil 75 1 R 1 R 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 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 Fou
67. licable Failure of any dealer to perform the required vehi cle Pre Delivery Inspection perform all applicable service bulletins and have the con sumer sign the PDI form prior to delivery may void the warranty Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage Use of the recommended POLARIS products for lubrication and maintenance as directed by the Owner s manual is highly recommended Should a failure occur dur ing the warranty period resulting from the use of non recommended products warranty coverage may be denied Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination The following items are excluded from warranty con sideration if the failure was due to wear or not the direct result of a defect Skis Ski wear rods Tracks Slide rails Suspension components Finished and unfinished surfaces Brake components Carburetor Throttle body components Seat components Engine components Clutches and components Drive belts Steering components Hydraulic components Batteries Circuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded f
68. linder Head Bolts 1 1 1 Oylinder Base Nuts 1 1 1 Ignition Timing BTDC 1 1 VES System C C 1 Coolant Level 81 1 1 R Coolant Hose 1 1 1 Coolant Circulation 1 1 1 Coolant Leaks 1 1 1 Spark Plugs 79 1 1 R 1 Exhaust Pipe 84 l I Exhaust Retaining 84 l 1 1 Springs Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 70 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page iso mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season BRAKES Hose Routing Hose Condition 1 1 1 1 1 1 1 1 Fluid Leaks l 1 l 1 Brake Pads 86 l 1 1 1 Brake Disc 1 l Parking Brakes 52 l 1 l 51 86 1 Brake Fluid 87 R FUEL MANAGEMENT Idle RPM 1 1 1 Throttle Lever 63 1 1 1 1 1 Oil Pump Lever 1 synchronize Throttle Position Sensor l 1 1 Fuel Lines 77 1 I Fuel Filter 77 EVERY 2000 3200 or EVERY 2 YEARS Oil Filter 80 R R Oil Lines 80 1 1 1 Air Box 1 1 1 1 ELECTRICAL Auxiliary Shut Off 54 1 1 1 1 Switch Throttle Safety Switch 62 1 1 1 1 1 Ignition Switch l 1 1 Taillight 54 1 1 1 1 Brakelight 54 1 1 1 1 Headlight 54 1 1 1 1 71 MAINTENANCE Periodic Maintenance Interval Tab
69. min 5 min N n 0 WINDCHILL CHART C Wind Actual Thermometer Reading C Spoed 5 2 1 4 7 30 3 16 19 22 25 28 31 34 37 40 43 46 KPH Equivalent Temperature _C Calm 2 a 4 7 40 13 16 19 22 25 28 31 34 37 40 43 46 5 8 3 o 4 7 41 14 18 22 25 29 32 36 39 43 46 50 58 57 16 2 2 6 10 18 17 21 24 28 32 86 39 43 47 50 54 58 62 1 0 24 3 7 11 15 19 22 26 30 34 38 42 45 49 53 57 61 65 32 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
70. n Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you re unable to continue up a hill turn the snowmobile downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill side of the snowmobile pull the rear of the snowmobile around and point the front end and skis downhill Remount the snowmo bile restart the engine release the parking brake and descend the hill carefully 17 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed Any servicing that requires operation without a belt must be performed by your dealer 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 clu
71. nded position and don t allow it to snap back into the housing Damage may result 5 Ifthe engine does not start after several attempts slightly depress the throttle no more than 1 41 open while cranking the engine When the engine starts immediately release the throttle CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running NOTICE Operating the vehicle immediately after cold starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle If cold drive away is attempted the engine RPM may stumble slightly to protect the engine Restarting an Engine If the rider stops the engine by pushing the engine stop switch down restart the engine using the normal starting procedure If the engine fails to start using the normal procedure 1 Push the engine stop switch down to the OFF position 2 Turn the key to the OFF position 3 With both switches OFF squeeze and hold the throttle in the wide open position 4 Crank the engine several times to clear the engine Release the throttle 6 Restart the engine using the normal starting procedure en 55 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 add
72. ntly 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 condi tions 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 14 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain X 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 moun tainous terrain Before riding in mountainous terrain call or log on to your local ava lanche advisory to get current weather and snow stability information
73. nual 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 Ibs 24 30 Nm Always carry spare spark plugs NOTICE Using non recommended spark plugs can result in serious engine damage A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile See your Owner s Manual Supplement 78 MAINTENANCE Spark Plugs Spark Plug Inspection Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the left side panel 2 Remove the spark plug cap 3 Using the special wrench provided in the tool pouch rotate the spark plug counter clockwise to remove 4 Reverse the procedure for spark plug installation Torque to specifi cation 5 Reinstall the spark plug cap Spark Plug Condition Normal Plug The normal insulator tip is gray tan or light brown There will be fe
74. nutes Take the drive belt off the snowmobile in extremely cold weather and warm it up Break snowmobile loose from the snow Poor engine performance Check for fouled plugs and water ice or dirt in the fuel tank or fuel line Loading snowmobiles onto trailers Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the snowmobile completely onto the trailer Push and pull it to finish loading if necessary Clutch malfunction Inspect clutch components See your dealer Slow easy clutch engagement Use fast aggressive throttle to engage clutch 109 WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty information contained in this manual Contact your POLARIS dealer for replacement parts service or warranty Your dealer receives frequent updates on changes modifi cations and tips on snowmobile maintenance which may supersede informa tion contained in this manual Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the fol lowing information Serial number Model number Dealer name Date of purchase Details of trouble experienced Length of time and conditions of operation 7 Previous correspondence
75. on Display Area 36 Inspection Pre Ride 48 Instrument Cluster 32 41 Intake 1 TT Intake Silencer 18 L Lights ne eer 89 Headlight Replacement 89 Taillight Brake Light 89 Lubrication 74 76 Rear Suspension 74 INDEX M Maintenance Interval Table 70 72 Maintenance Program 69 Maintenance Recommendations 9 Maneuverability 18 Metric Standard Display 38 N eet etre aie ied iem 6 Odometer Engine Hour Display 37 Oil Change Chaincase 75 Ou Filter eoe tmo 80 Oil Injection System 57 Oil Level Chaincase 75 Oil Level Injection 61 Oil Eines cry 80 Oil Recommendations 56 Operating in Deep Snow 16 Operation Warning 24 25 Operator 8 20 Overheating Engine 82 P Parking Brake Lever Lock 52 Passenger Warning 22 Playback Function 37 Polaris Products Part Numbers 104 Pre Ride Checklist 48 Pre Ride Suspension Inspection 49 Pressure Cap Warning 21 R Rail Slide 101 Recoil Rope Inspection 53 Registration Warranty 112 123 INDEX R Reverse Operation 64 65 Reverse Warnin
76. ons 32 Mode Set Switch 32 Throttle Safety Switch 62 T Taillight Brakelight Replacement 89 Throttle Lever 63 Throttle Lever Inspection 50 Throttle Safety Switch 62 Throttle Safety Switch Inspection 50 Tool Kit 5e os en ee A 28 Towing rem reser 67 Track Alignment 98 95 Lubrication 95 Tension 96 97 Track Care for Storage 103 Track Inspection 53 Track Maintenance 95 98 Track 10 Track Warm Up 58 Track 23 Transporting the Snowmobile 102 Troubleshooting Drive Belt 109 Troubleshooting Engine 105 107 Troubleshooting Suspension 108 TuneUp cv ER ess RE tms 102 V Vehicle Identification Numbers 7 Windchill 00000 20
77. ood 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 condi tions you may encounter Such equipment may include but is not lim ited 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 cel lular telephone Always carry the owner s manual on your snowmobile For added pro tection purchase and carry the following items on your snowmobile as well Spare Drive Belt Winter Survival Kit Extra Set of Spark Plugs Trail Map Tow Rope First Aid Kit Extra Oil Tool Kit Fuel Deicer 12 SAFETY Operator Safety Rider Capacity This snowmobile is designed for a single rider only Never carry a pas senger 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 opera tion and speed limits Always be alert and pay attention to the t
78. or will read dET see illustration The engine will enter a imp 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 30 Severe detonation detected RPM will be limited FEATURES Detonation Elimination Technology DET The most likely causes of severe detonation are outlined in the trouble shooting table below DET Troubleshooting Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol non ethanol fuel resistor installed Verify 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 1096 Ethanol fuel Improper engine modifications Do not modify the engine 31 FEATURES Instrument Cluster Rider Information Center Check Engine Indicator High Beam Indicator Over y Temperature V H Ft EA Park Brake Indicator loj Indicator 50088 C3 8588888751 Reverse FON M Indicator Indicator
79. painted surfaces Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint The snowmobile should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components 102 MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Mainte nance Table beginning on page 70 Clutch and Drive System Remove the drive belt and store in a cool dry location Do not lubricate clutch components except the driven clutch shaft bushing as outlined in the Master Repair Manual See your dealer Engine Protection Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine parts during storage Whenever the snowmobile is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the container running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel Do not allow the snowmobile to run out of fuel Electrical Connections Replace worn or frayed electrical wire and connectors Be sure wi
80. pward and rearward to remove it 93 MAINTENANCE Clutch System Drive Belt Installation 1 94 Drop the drive belt over the drive clutch and pull back the AA slack The belt cord line ZA Y should be flush with or 2 N slightly above the outer cir 0 7 NN cumference of the driven A uc NN clutch sheaves The belt will seat itself in the driven clutch during the break in period M Adjust the belt ride out after Ah d NS the break in period by read R justing belt deflection 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 out lined in the belt removal procedures Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves 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 Rotate the L wrench to tighten the sheaves Remove the wrench and store in the tool kit Reinstall the side panel Break in the new belt See page 57 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 hoi
81. r 4 rear chaincase nuts 72 Hood Side Panel The hood and side panels of the snowmobile protect the operator from moving parts Never oper ate 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 MAINTENANCE 1 4 Turn Fasteners Removing the hood is not recommended Any service requiring the removal of the hood should be performed by an authorized POLARIS dealer 73 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS Premium AII Sea son Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 70 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 sus pension For more information about suspension lubrication and adjust ments see your POLARIS dealer 74 MAINTENANCE Lubrication Chaincase Oil Check and change the chaincase oil at the intervals outlined in the main tenance charts beginning on page 69 Maintain the oil level at the top of the
82. rail 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 illu minated by the headlight 13 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 suffi cie
83. rake Indicator This indicator illuminates when the parking brake is engaged It will also illuminate when the service brake is in use See page 52 Reverse Indicator This indicator flashes when the transmission is in reverse See page 65 33 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 tempera ture and diagnostic display mode Setting changes must be made with the engine running or with the vehi cle 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 34 FEATURES Instrument Cluster Rider Information Center l Tip 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 dis play see page 36 Speed Display The speed display area displays either vehicle speed or engine speed To change the display see page 36 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately If
84. rap condition Check rail slide condition 101 Check track tension 96 Check ski runner skag condition 101 Check ski spindle bolts for tightness Check tie rod end nuts for tightness 49 PRE RIDE INSPECTIONS Before Starting the Engine Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start the engine without checking all vehicle components to be sure of proper operation WARNING Operating the vehicle with worn damaged or malfunctioning components could result in serious injury or death Never start the engine without checking all vehicle components to be sure of proper operation Read and Understand Your Owner s Manual Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience 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 func tion smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately Throttle Safety Switch Test the throttle safety switch system before the snowmobile is operated See page 62 50 PRE RIDE INS
85. required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS Industries in order to register your vehicle in your new country You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and notices regarding your vehicle 115 WARRANTY How to Get Service If Purchased From A Private Party If you purchase a POLARIS product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind other than safety bulletins Vehicles reg istered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic war ranty For questions call POLARIS Customer Assistance see page 110 116 WARRANTY U S A
86. ring harness is properly secured away from sharp edges steering linkage moving parts and hot exhaust parts Track and Suspension Moderate track tension should be maintained during summer storage The snowmobile should be supported off the ground to allow the track to hang freely 103 POLARIS PRODUCTS Part No Description Engine Lubricants 2870791 Fogging Oil 12 oz Aerosol 2875035 Premium 2 Cycle Semi Synthetic Oil qt 95 I break in only 2875036 Premium 2 Cycle Semi Synthetic Oil gal 3 8 1 break in only 2877882 VES Gold Plus 2 Cycle Oil qt 95 1 2877953 VES Gold Plus 2 Cycle Engine Oil 2 qt 1 9 1 2877883 VES Gold Plus 2 Cycle Engine Oil gal 3 8 1 2877884 VES Gold Plus 2 Cycle Engine Oil 2 5 gal 9 5 1 2877887 VES Gold Plus 2 Cycle Engine Oil Itr 2877888 VES Gold Plus 2 Cycle Engine Oil 4 Itr Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 95 1 2872951 Synthetic Chaincase Lubricant 12 02 355 ml Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 0z 89 ml 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogelt Coolant 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOTA Brake Fluid 2872893 Engine Degreaser 28
87. roducts If you use fuel with up to 10 ethanol sometimes labeled oxygen ated do not add deicers or additives that contain any form of alcohol 60 OPERATION Oil Low Oil Level Always maintain the oil level between the mark and the bottle neck Do not fill the bottle neck See page 56 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 Addoilas needed before operating NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refu eling Add oil as needed The oil bottle cap is vented to allow proper oil flow See your POLARIS dealer for recommended replacement parts 61 OPERATION Engine Stop Switch Push down on the engine stop switch H to ground ES out the ignition and stop the engine quickly Pull the switch up to the ON position to allow restart ing di 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
88. rom warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 114 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from POLARIS
89. situation that may result in property damage SAFETY Operator Safety Follow the recommended maintenance program beginning on page 69 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals A WARNING Driving a snowmobile requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger They will reduce your alertness and slow your reaction time Snowmobiles are capable of traveling at high speeds Use extra caution to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All POLARIS snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aerody namically 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 haz ard and lead to bodily injury The warranty on your entire machine is terminated if any equipment has been added or any modifications have been made to increase the speed or power of the snowmobile SAFETY Operator Safety Stay Clear of Track Your snowmobile is
90. st safely lift and support the rear of the snow mobile 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 H 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 slide 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 addi tional wheel kits are available See your dealer for more information Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty 95 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 cor r
91. stem to cool Never perform this procedure with the engine running 1 Open the side panels and remove the hood See page 73 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 84 MAINTENANCE 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 Jam Adjuster Nut Bolt 5 Tighten the jam nut while holding the adjuster bolt Torque to 21 ft Ibs 28 Nm 6 Reinstall the side panels 7 Release the brake lever lock 85 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile See page 51 Brake pads must be replaced when the brake pad material becomes thin ner than the backing plate approximately 1 161 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 trave
92. t Tether Switch Option Interrupts ignition circuit 66 OPERATION Daily Storage At the end of each ride park the snowmobile on a level surface and sup port it at the rear with an appropriate track stand The track should be suspended approximately 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 serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in the towed object WARNING Braking distances increase when towing loads Slow down to maintain control of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damage to the steering components Remove the drive belt before towing and have someone ride on the towed snowmobile to opera
93. t 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 responsi ble for ensuring that the specified maintenance is performed POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 68 MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and perform service checks as out lined in this manual Record maintenance and service in the Mainte nance Log beginning on page 119 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 per formed by a qualified service technician For continued optimum perfor mance 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 becom
94. t 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 etha nol fuel resistor is installed The check engine light may also display in this condition as this could cause detonation ETHANOL OR OTHER EMT CR P OXYGENATED GASOLINE e H A 10 ETHANOL Factory Delivery e d 24 OHM ANY FUEL WITH ETHANOL P or LESS THAN 91 OCTANE 87 Octane Minimum NON ETHANOL GASOLINE NON ETHANOL 91 OCTANE Maximum Performance Resistor 29 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 system is activated In most cases this the check engine light will illuminate 27 i and you may notice decreased engine j y performance and RPM when the DET mf Ij ET Oc is temporary and the operator does not need to take any action The engine will return to its normal performance E31 488888 automatically ae If severe detonation occurs the check engine light will begin to flash steadily and the gauge indicat
95. tch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the snowmobile into motion but always operate within safety limits Maneuverability While much control and maneuverability is achieved through the steer ing 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 18 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently and even the most docile condi tions 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 driv ers 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 bal ance in executing turns traversing hills etc Always start on a smooth level area to begin building your operating experi
96. te the brake and steering when necessary NOTICE Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 67 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 con trol information label and a factory installed emissions informa tion hangtag These items are required by U S Environmental Protection Agency regulations The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover The ECI label should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is avail able to your qualified service technician Reverse if equipped mus
97. th water Never exceed a 60 antifreeze 40 water mixture See page 104 for POLARIS products Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are Coolant bottle overflow tank Pressure cap Connecting hoses Always maintain the coolant level at or Full Cold Mark slightly above the FULL COLD mark on the coolant bottle when the engine is cold l 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 81 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 106 BB eeHOE 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 driv
98. the area behind your vehicle is clear 3 Push the yellow reverse button on the left hand control for one sec ond then release The engine will automatically reduce RPM and start a reverse rotation A flashing reverse light on the instrument panel will indicate that the 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 instru ment panel will shut off 3 Apply the throttle slowly to make sure the transmission is in for ward 65 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 62 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 circui
99. ustments Fine Tuning Your Suspension Set Up The primary adjustment for overall vehicle balance is RTSS preload Adjust the factory set preload to the recommended setting for your weight and then test ride Additional minor adjustments can then be made to the spring preload to adjust the feel of the vehicle Do not exceed the minimum and maximum installed length requirements See page 42 For more ski lift transfer reduce spring preload by increasing the installed length Rotate the spring 1 2 full turns counter clockwise when viewed from bottom This will enhance maneuverability mak ing the snowmobile more flickable although it may hinder climbing performance For less ski lift transfer increase spring preload by reducing the installed length Rotate the spring 1 2 full turns clockwise when viewed from bottom This will improve climbing ability and rider control To control the overall balance of the vehicle use the following guideline More rear track shock spring preload increases ski pressure Less pre load decreases ski pressure Spring preload can affect bottoming resistance More preload means less bottoming Less preload means a softer ride and more bottom ing Both adjustments will affect overall balance and ski pressure After adjusting RTSS preload to your satisfaction the front track shock FTS spring preload and independent front suspension IFS spring pre load can also be adjusted See page 46
100. ution POLARIS engineers continuously investigate ways to reduce emission levels of two stroke engines We expect our efforts to lead to the reduc tion of potential air pollution In addition to our technological research we encourage government agencies manufacturers distributors dealers ecologists and other interested parties to work together to develop data on environmental topics INTRODUCTION 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 H right side of tunnel Engine Serial Number on recoil housing Key Number SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols 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
101. w combustion deposits The electrodes are not burned or eroded This indi cates 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 79 MAINTENANCE 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 fil ter 80 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 oper ated at extremely low temperatures greater protection may be required Please see your POLARIS dealer When adding or changing coolant POLARIS recommends using Pre mium 60 40 anti freeze coolant which is already premixed and ready to use Do not dilute wi
102. y 19 E Electrical Connections Care for Storage 103 Emission Control Information 68 Emissions Limited Warranty 117 118 Engine Break In 56 57 Engine Overheating 82 Engine Protection for Storage 103 Engine Restarting 55 Engine Safety 10 Engine Starting 55 Engine Stop Switch 62 Environment Preservation 6 Exhaust System 84 Fasteners Hood and Side Panel 53 Fluid Change 75 Coolant 82 Fluid Level Brake Fluid 87 75 Coolant 81 F BUG eo eer HER dn 59 F elFiltet 2 77 Fuel Lines 00 77 Fuel Premix Initial 56 Fuel Pump aulis s TI Fuel Recommendation 59 Fuel 29 Fuel System Deicers 60 Fuel 59 H Handlebar Adjustments 47 Handlebar Angle 47 Handlebar Position 47 Headlight Adjustment 28 Headlight Lamp Replacement 89 Hood Fasteners 53 Hood Side Panel 73 Hot Surface Warning 23 Ice and Snow Build up 16 Inadequate Snow Conditions 16 Indicator Lights 33 Informati
103. your vehicle 10 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 estab lished safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever 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 com fortable 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 SAFETY Operator Safety Disabled Operators Safe operation of this rider active vehicle requires g

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