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Polaris 600 RMK Shift User's Manual

1. Wind Actual Thermometer Reading C Speed 5 2 3 4 7 0 43 16 19 22 25 28 31 34 37 40 43 46 KPH Equivalent Temperature Calm 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 3 0 4 7 11 14 18 22 25 29 32 36 39 43 46 50 53 57 16 2 2 6 10 13 17 21 24 28 32 36 39 43 47 50 54 58 62 24 1 3 7 11 15 19 22 26 30 34 38 42 45 49 53 57 32 0 4 8 12 16 20 24 28 32 36 39 43 47 51 55 40 1 5 9 13 17 21 25 29 33 37 41 45 49 53 48 1 5 9 13 18 22 26 30 34 38 42 46 50 56 2 6 10 14 18 22 26 31 35 39 43 47 64 2 6 10 15 19 23 27 31 35 40 44 48 72 2 7 11 15 19 23 28 32 36 40 45 80 3 7 11 15 20 24 28 33 37 41 45 88 3 7 12 16 20 24 29 33 37 42 46 16 Frostbite gt gt 30 10 min 21 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protec tion Read and follow the instructions of the decals and other warnings on the snowmobile carefully If any of the decals depicted in this manual
2. ce eee 51 89 92 Break In Engine 57 58 Bulbs Replacing 93 C Cargo 28 Chaincase 77 78 Clutch Alignment Offset 94 Clutch Center Distance 94 Clutch Cover Warning 22 Clutch System 94 97 Cl tches i cR eine 18 84 Coolant High Temperature Light 85 Coolant 84 Cooling System 84 87 Cooling System Bleeding 86 87 Cooling System Flushing 85 D den dtp e 29 Detonation Elimination Technology 29 Digital Display 31 Digital Display Programs 33 37 Disabled Operators 13 Drive Belti certe uana esea 18 Drive Belt Adjustment 97 Drive Belt Condition 95 Drive Belt Deflection 97 Drive Belt Installation 95 Drive Belt Removal 96 Drive Belt Troubleshooting 115 128 D Drive Chain Tension 88 Driver Awareness 14 Driving Downhill 16 Driving in Hilly Terrain 17 Driving on Slippery Surfaces 17 Driving Responsibly 20 E Electrical Connections 109 Emission Control Information 69 70 Emission Control Label 69 Emission Control Maintenance 69 Engine Break In 57 58 Engine Protection
3. 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 brake master cylinder reservoir cover and gasket 2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 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 brakes to lock resulting in serious injury or death Always add brake fluid to the fill line as recommended 7 After bleeding is complete refill the reservoir to the proper level See page 91 8 Reinstall the gasket and cover 92 Lights Removing Halogen Bulbs Do not
4. 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 A The safety alert symbol on your vehicle or in this manual indicates the potential for serious injury WARNING A WARNING indicates a potential hazard that may result in serious injury or death CAUTION A CAUTION indicates a potential hazard that may result in minor injury NOTICE A NOTICE indicates a situation that may result in damage to the vehicle SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 71 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals 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 critic
5. 108 Engine Stop Switch 63 Engine 56 Environment Preservation 6 Exhaust 83 Eye 12 F Fuel Filter 2 ee 82 Fuel 82 Fuel oe ean ce 82 Fuel 82 Fuel Recommendations 61 Fuel 60 Fuel System Deicers 61 G Gauge Cleaning 38 H Handlebar Adjustments 46 47 Handlebar Angle 47 Handlebar Position 47 Headlight Adjustments 28 Helmet Recommendations 12 Hood 50 Hot Surface Warning 23 l Ice and Snow Build up 16 IESU ag Atte tigen 39 Instrumentation 30 38 Intake 81 Intake Silencer 18 L Lights 5o en Gee addons Baa 93 Limiter Strap Position 44 Low Oil Indicator Light 62 Lubrication 75 78 Chaincase 77 78 Driveshaft Bearing 76 Front Suspension 75 Rear Suspension 75 Throttle Cable 76 M Maintenance Interval Table 72 74 Maintenance Program 71 Maneuverability 18 MED 30 Digital Display 33 Digital Display
6. 33 FEATURES Instrumentation MFD Digital Display Programs Performance Program Trip Settings Trip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge The fuel symbol and the last fuel bar on the MFD gauge if equipped will blink when the fuel level reaches 1 8 of a tank The Trip odometer records distance traveled and the fuel symbol continues to blink until enough fuel is added to raise the level above 1 4 of a tank The Trip F odometer will automatically reset to zero after refueling Engine Program Press and release the MODE button until the engine program screen is active The default display for this screen includes engine hours electri cal system voltage level fuel level 1f equipped and either engine cool ant temperature air temperature accessory or altimeter accessory Press and release the SET button to cycle through the following screens hour meter engine temperature air temperature available as an acces sory and altimeter available as an accessory Hour Meter 1 The hour meter records the total hours of engine operation since manufacture This LI l meter cannot be reset Engine Temperature A thermometer measures water temperature giving an indication of engine temperature 34 Instrumentation MFD Digital Display Programs Engine Program Air Temperature accessory Th
7. 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 machine 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 TIP Do not spray fogging oil into the plenum Remove the plenum and spray the fogging oil into the boost box Continue spraying until the engine stops 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 See page 68 108 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors Be sure wiring 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 machine should be supported off the ground to allow the track to hang freely Transporting the Snowmobile Whenever the snowmobile is transported 1 Be sure fuel cap and oil cap are installed correctly 2 Always tie the snowmobile to the transporting unit securely using suitable straps 3 Remove the ignition key to prevent loss 109 POLARIS PRODUCT
8. Riding Apparel Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 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 mm PELARIS the weather forecast especially the windchill and dress accordingly See the chart on page 21 A 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 pro tection 12 SAFETY Operator Safety Disabled Operators Safe operation of this rider active vehicle requires good judg
9. See page 47 Accessory Cargo System The maximum weight capacity for the rear cargo area is 15 16 7 kg Always secure cargo before operating Do not exceed the cargo weight limit Do not allow a passenger to sit on the seat back or the cargo area 28 FEATURES Detonation Elimination Technology DET A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing and adding fuel This results in decreased engine RPM and performance Effect of DET The DET system prevents damage to the engine from detonation while developing the maximum power of the engine safely If the system senses detonation beyond a preset limit it retards ignition timing and adds fuel to reduce the detonation and prevent engine damage When the detonation returns to a permissible level the system will return spark and fuel to normal allowing the engine to run at rated power levels Sensor Fail Safe The DET includes a sensor fail safe system to prevent the engine from damage if the sensor fails becomes disconnected or is unable to detect detonation The rider will experience a loss in power The sensor must be reconnected or repaired to regain full power TIP The check engine light will flash six times if the sensor fails or becomes disconnected 29 FEATURES Instrumentation MFD Component Identification Item Analog Gauge if equipped Digital Gauge Check Engine Indic
10. 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 must not be engaged during engine tune ups 69 MAINTENANCE Emission Control Information 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 70 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and perform
11. Agency regulations applicable to snowmobile emissions Polaris warrants that the engine 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 snowmobile engine starts on the date when the engine is first purchased and continues for a period of 200 hours of engine operation 4000 kilometers 2485 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This engine emissions limited warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty This includes all com ponents whose failure increases the snowmobile engine s emissions Replacing or repairing other components not covered by this warranty is the responsibility of the snowmobile owner 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 prod ucts 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 WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCH
12. All Engine Stop Switch Interrupts ignition circuit All Choke if equipped Floods engine Half throttle or less Throttle Safety Switch Interrupts ignition circuit All Tether Switch if equipped Interrupts ignition circuit All 65 OPERATION Electronic Reverse PERC Electronic reverse will activate only if the engine RPM is below 4000 The maximum engine RPM will be 6000 when in reverse WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle Look behind the snowmobile before and while backing Avoid sharp turns Apply throttle slowly 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 66 OPERATION Electronic Reverse PERC Engaging Reverse 1 2 TIP 4 TIP Stop the snowmobile and leave the engine idling Make sure the area behind your snowmobile is clear Push the reverse button on the left hand control for one second then release The engine will automatically reduce RPM and start a reverse rotation A reverse light on the instrument
13. Leaks 1 1 1 1 Brake Pads 89 1 1 1 Brake Disc 1 l 1 Parking Brake 52 1 1 1 51 89 1 Brake Fluid 91 R FUEL MANAGEMENT Idle RPM 1 1 1 Throttle Lever 50 64 1 1 1 1 1 Oil Pump Lever 1 1 synchronize Throttle Cable 76 L L L Vent Lines 1 1 l Throttle Position Sensor 1 1 Fuel Lines 82 l 1 I 1 Fuel Filter 82 R R Oil Filter 82 R R Oil Lines 82 1 1 Air Box Plenum l 1 1 1 Fuel Injectors 1 1 ELECTRICAL Engine Stop Switch 63 1 1 1 1 Throttle Safety Switch 63 1 1 I 1 l Ignition Switch 1 1 1 1 Taillight 55 1 1 1 1 Brakelight 55 1 1 I 1 l Headlight 55 1 1 1 1 1 73 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 450 mi 500 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CHASSIS Ski Toe Alignment 1 1 1 Suspension Mounting 1 1 1 1 1 Bolts Steering Fasteners 1 1 1 1 Rear Suspension 1 1 1 1 I Fasteners Walker Evans Air See your dealer for service Shocks at 1500 mi 2000 km Suspension Shock Oil 1 1 1 I Cooling Fins Shroud 1 1 1 I Drive Shaft Bearings 76 L L L Jackshaft Bearings 107 L L L 1 Skags Wear Bars 105 1 1 1 1 I Ski Saddle Spindle 1 1 1 1 1 Bolts Drive Chain Tension 88 1 1 1 1 1 Hood Latches 50 1 1 1 1 1 Rear W
14. Ski Saddle and Spindle Bolts 54 Hood Straps Latches 50 Seat Latches if equipped N A Rear Wheel Idler Bolts 54 101 Tether Switch Strap 55 Track Alignment Condition 53 102 Rail Slide Condition 106 Chaincase Oil Level 77 Oil Level 62 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 A WARNING Operating the vehicle with worn damaged or malfunctioning components could result in serious injury or death Never start the engine without check ing 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 i
15. all times for assurance against fuel line icing more than normal pulls to start Incorrect throttle SEE YOUR DEALER freeplay or faulty switch Engine requires Poor fuel Replace with fresh winter fuel Not enough fuel get ting to engine SEE YOUR DEALER Engine backfires but fails to start Spark plug wires may be on wrong cylinder Reinstall spark plug wires to the cor responding cylinder 113 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bot toms too easily Set static sag see page 43 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Rides too stiff in rear Check for binding suspension components and grease all pivot points Set static sag see page 43 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Too much weight transfer when climb ing Set static sag see page 43 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Move limiter strap to high position see page 44 Too little weight transfer when climb ing Front end pushes Set static sag see page 43 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Move limiter strap to low position see page 44 Check for worn skags Check for binding front suspension shafts steering co
16. equipped with a deep lug track Track lug damage may occur Keep high speed use to a minimum including frequent slow speed intervals for track cooling 53 PRE RIDE INSPECTIONS Before Starting the Engine 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 Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 101 Rear idler adjusting bolt locknuts Tightness Torque arm bolts Tightness Carrier and bogie wheel bolts Tightness Front torque arm limiter strap Condition Rail slide Condition 106 Track Tension 100 All rear suspension components Lubrication 75 Ski runner skag Condition Ski spindle bolts Tightness Tie rod end nuts Tightness 54 PRE RIDE INSPECTIONS Start the Engine and Check Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never engage the starter when the engine is running Never start the engine without checking all vehicle components to be sure of proper operation See Before Starting the Engine beginning on page 50 Engine Stop Switch Check the auxiliary shut off switch for proper operation Push the switch down to stop the en
17. may result Most cooling systems are equipped with a filter that should be periodically inspected or replaced 86 MAINTENANCE Cooling System Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main tenance Table beginning on page 72 Perform the bleeding procedure when the engine is cold 1 Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark 2 Elevate the front end of the machine slightly to aid in bleeding of the heat exchangers 3 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 Add coolant to the coolant bottle to the maximum mark 5 Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air 6 Stop the engine and check the coolant bottle level Fill as required 7 Feel the heat exchangers under the running boards If the system is bled properly they ll be warm to the touch If they re not repeat step 5 Lift the front of the machine slightly to assist in the bleeding 8 Replace the pressure cap and carefully lower the front end of the machine 87 MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip To obtain correct chain tension 1 Rotate the d
18. panel will indicate that the transmission is in reverse Apply the throttle slowly to make sure the transmission is in reverse If the engine stops running the snowmobile will be in forward gear when its restarted Disengaging Reverse l 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 Push the reverse button for one second and release The engine will slow and begin to rotate forward The light on the instrument panel will shut off Apply the throttle slowly to make sure the transmission is in forward 67 OPERATION Daily Storage At the end of each ride park the snowmobile Fe es on a level surface and support it at the rear E with an appropriate track stand The track should be suspended approximately 4 10 off the ground cen Remove the key and cover the snowmobile Towing Do not use the front bumper to pull or drag the snowmobile The front bumper is not designed for this type of use and may detach from the vehicle if force is applied 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 o
19. position and don t allow it to snap back into the housing Damage may result 4 Repeat the cranking procedure as needed until the engine starts TIP It may require as many as eight to ten pulls to prime the fuel system and start the engine if the fuel tank has been completely emptied 56 OPERATION Engine Break In No single action on your part is as important to long trouble free machine life as proper break in of a new or rebuilt engine Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel This in addition to the lubrication supplied by the injec tion system will assure proper engine break in NOTICE 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 machine speeds to reduce friction on all close fitting machined parts allowing them to break in slowly without damage Use of any lubricants other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris lubricants for your vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the machine 57 OPERATION Engine Break In Oil Injection System Always fill the oil reservoir when refueling NOTICE Serious engi
20. service checks as out lined in this manual Record maintenance and service in the Mainte nance Log beginning on page 125 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 become 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 71 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions You may need t
21. snowmobile dealers in North America and is transfer able 120 days after the original purchase date free of charge through any Polaris snow mobile dealer Coverage on Snow Check units is automatic Although you do not receive a warranty card your dealership should have printed a copy of the warranty reg istration form This form is your proof of warranty Consumer Exclusions Each repair visit after the first twelve months of standard warranty coverage is subject to a 50 deductible The free Second Year Engine Service Contract applies to the first 5 000 miles or two 2 calendar years from date of purchase whichever comes first Tampering with the odometer shall void all warranties service contracts No extensions to coverage under this engine service contract can be given Used snowmobiles are not eligible under this program Snowmobiles used for commercial purposes or for racing are excluded from coverage Coverage Coverage for second year engine failures due to defects in materials and workmanship will be determined by Polaris in its sole discretion Coverage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes Damage due to accident fire explosion theft or other causes beyond Polaris contro
22. 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 experience 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 Operat
23. 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 and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2008 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor 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 Printed in U S A
24. touch a halogen bulb with bare fingers Oil from skin leaves a residue causing a hot spot that will shorten the life of the lamp If fin gers do touch the bulb clean it with an alcohol moistened towel 1 Remove the plenum Bulb ering from the headlight assembly Spring Lift the rubber boot to expose the bulb Harness ga Push down on the spring to release it from the housing With the wire harness attached to the bulb withdraw the bulb from the housing Grasp the bulb by its metal base and carefully separate the bulb from the harness Installing Halogen Bulbs 1 Hold the bulb by its metal base and install it into the wire harness 2 Insert the bulb into the housing 3 Connect the spring to the housing 4 Carefully flip the spring back into the housing placing it around the wire harness 5 Reinstall the plenum covering on the headlight assembly 6 Adjust headlight aim See page 28 Replacing Taillight Bulbs 1 Remove the screws securing the taillight lens 2 Remove the bulb and install a new bulb 3 Reinstall the lens 93 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage wear or belt residue To maintain optimum performance clean with non oil based cleaners such as isopropyl alcohol WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern see your dealer immediately Do not operate the sno
25. within five seconds the gauge will automatically save the new setting 35 FEATURES Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active This screen will always display electrical system voltage level and fuel level if equipped Press and release the SET button to cycle through the following screens maximum vehicle speed maximum engine RPM and service interval reminder Maximum Speed Maximum RPM The gauge automatically logs the maximum speed and engine RPM even if the history program is not active in the display 1 Enter the History Program 2 Press and release the SET button until one of the two screens is active The MPH and RPM values are both reset at the same time Reset the values before each run to obtain accurate readings 3 Press and hold the SET button for three seconds to reset the recorded maximum values for both MPH and RPM TIP Due to electrical noise the MFD may occasionally display MAX MPH RPM values that are not representative of actual values 36 FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service reminders When the logged hours reaches the desig nated service interval set by the user the gauge provides a reminder that service is B ai due
26. 2009 Owner s Manual P N 9921613 600 800 RMK SHIFT 700 800 RMK 155 800 DRAGON RMK 800 ASSAULT RMK 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 sc beter tetesle sues ered 8 This section describes safe vehicle operation and identifies warning decals and their locations Features 24 2066 whee nee ea we x week 26 This section identifies the locations of your snowmobile s controls and features The Perfect Fit 39 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 49 This section explains procedures that must be performed before riding Operation 56 This section explains proper engine break in operation of features and general operating procedures 69 This section defines your role and your dealer s role in your snowmo bile s regular maintenance Polaris Products 110 Troubleshooting 111 Warranty sesir cence n REESE 116 Maintenance Log 125 Index sere DES 128 INTRODUCTION Important N
27. 84 MAINTENANCE Cooling System Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine cool ant temperature becomes too hot for safe continued operation of the engine If you must drive your snowmobile after the high temperature indicator light has come on drive slowly and stop frequently to allow the engine to cool down Driving in deep snow will also help cool the engine See your dealer for service Add coolant if the level is low TIP Engine performance will be reduced if you continue operating when the high temperature light is on 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 85 MAINTENANCE Cooling System Bleeding the Cooling System A 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
28. AFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is a requirement for operation of your snowmobile NOTICE Driving in too little snow will result in excessive wear and damage to the slide rail track and or engine WARNING Inadequate cooling and lubrication will lead to overheating of the slide rail and track causing premature wear damage and failure which can result in serious injury Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating for prolonged periods on ice hard packed surfaces or roads Operating in Deep Snow If the snowmobile becomes stuck in snow clear the running board area of snow then step down the snow in front of the snowmobile so that when the throttle is opened the snowmobile will be able to climb up and over the snow 19 SAFETY perator 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 machine 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 machine before attempting ambitious maneuvers 20 A
29. ANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATE 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 inconsistent with the controlling state law 123 WARRANTY Snowmobile Engine Emissions Limited Warranty 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 snowmobile has been used in racing competi tion 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 can deny an emissions warranty claim if any specified critical emissions related maintenance is not performed Performance of other scheduled main tenance is strongly recommended but is not necessary to keep the emissions related warranty valid Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your snowmobile Polaris recommends that you contact an authorized Po
30. Do not leave brake engaged for more than five minutes Before starting the engine check throttle brake and steering for proper operation Make sure hood is latched Be seated and in posi tion to control the vehicle Oil injection system Use unmixed fuel only Check oil level when refueling 25 FEATURES 26 ONAAARON Front Bumper do not use for pulling or dragging the snow mobile Hood Headlight Windshield Mountain Bar if equipped Handlebar Seat Taillights 10 11 12 13 14 15 16 Rear Bumper Snow Flap Track Suspension Tunnel Side Panel Ski Nosepan ouogesomc 13 14 10 Fuel Filler Cap Ignition Switch MFD Multi Function Display Engine Stop Switch Throttle Control Recoil Starter Handle Hood Hold Down Straps Brake Lever FEATURES Parking Brake Handlebar Grip Warmer Switch Thumbwarmer Switch Electronic Reverse Button MFD Control Headlight Dimmer Switch 27 FEATURES Headlight Dimmer Switch Use the headlight dimmer switch to adjust the headlights between high beam and low beam Switch headlights to low beam when meeting oncoming traffic Dimmer Switch Adjustable Headlights Move the adjuster to the left to lower the headlight beam Move the adjuster to the right to raise the headlight beam Adjustable Steering The adjustable steering system allows you to adjust the handlebar posi tion to fit your style of riding
31. ED 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 autho rized 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 119 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 applicable Failure
32. LING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris 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 Recalls 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 Warranty 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 per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the custo
33. Pantone 7427 C 600 RMK Shift 800 RMK Shift 100 155 800 RMK 155 800 Dragon RMK _ 800 Assault RMK bile Owner s Manual r Maintenance and Safety POLARIS The Way Out Pantone 7427 C 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 9921613 Rev 01 Printed in USA 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 WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure
34. Programs 34 37 MFD Settings 32 N NOISE xx eek ete eee el cee 6 Oil Filtet oit Rs 82 Oil Injection System 58 Oil Level sini ec eR ls 62 OIL Emes indul Res 82 Oil Recommendations 58 Oil 77 Oil Engine 62 Operating in Deep Snow 19 Operation Waming 24 25 P Parking Brake Lever Lock 52 Passenger Warning 23 Polaris Products 110 Pre Ride Checklist 49 55 Pressure Cap Warning 22 R Rail Slide 106 Recoil Rope 51 Reverse Operation 66 67 Reverse Warning 24 Rider Capacity 13 S Safety iced ev oe ee eG REUS 8 21 Safety Decals 22 25 Sag Settings 43 Shock Components 40 Shock Compression Valving 45 Shock Spring Preload Front 41 Shock Springs Front 41 Shocks 40 Shocks Standard 40 hose ded e onde des 105 Ski Alignment 104 Slide Rail and Track Cooling 58 Snow Build up 16 Snow Conditions 19 Spark 79 80 Speed sa he ee ahs ators 13 Spring Preload 43 Starting the Engine 56 Steering Adjustments 28 Steerin
35. S Part No Description Engine Lubricants 2870791 Fogging Oil 12 oz Aerosol 2871098 Premium 2 Cycle Engine Oil qt 2871097 Premium 2 Cycle Engine Oil gal 2871240 Premium 2 Cycle Engine Oil 2 5 gal 2871721 Premium Gold Synthetic 2 Cycle Engine Oil qt 2871722 Premium Gold Synthetic 2 Cycle Engine Oil gal 2872347 Premium Gold Synthetic 2 Cycle Engine Oil 2 5 gal 2874438 VES II Synthetic 2 Cycle Engine Oil qt 2874439 VES II Synthetic 2 Cycle Engine Oil gal 2874443 VES II Synthetic 2 Cycle Engine Oil 2 5 gal Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogel Coolant 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT 4 Brake Fluid 12 oz 2872893 Engine Degreaser 12 oz 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carb and Throttle Body Cleaner 110 TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two cycle engine repair see your dealer if technical pr
36. SErVCE will flash in the odometer SERVE area and ENG will flash in the icon area for five seconds each time the engine is started until the service reminder is reset Use the following procedures to reset the reminder To reset the reminder at the existing interval 1 2 3 4 Enter the History Program Press and release the SET button until the service interval screen is active Press and hold the SET button for ten seconds continuing to hold even after the display begins to flash When the display stops flashing release the button The service interval has been reset To reset the reminder at a new interval 1 2 3 4 Enter the History Program Press and release the SET button until the service interval screen is active Press and hold the SET button for five seconds until the hours begin to flash Immediately release the button Press the button again up to five times to advance the reminder in 20 hour increments The maximum interval is 200 hours To disable the service interval reminder press the SET button once after reaching 200 hours on the display The gauge will display OFF 37 FEATURES Instrumentation Gauge Cleaning 1 Wipe the gauge face as needed using a clean cloth and a mild soap and water solution Wipe dry with clean soft cloth 2 Clean the back side of the gauge using a clean cloth and a mild soap and water solution Do not remove the electrical connecto
37. THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable Use only Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in Non compliance with government industry requirements Voiding of warranty Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service Tether Switch The accessory tether switch is available for all models Order part num ber 2870668 48 PRE RIDE INSPECTIONS Pre Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile Procedures are outlined on the refer enced pages Look for a checkmark on the referenced pages to locate the pre ride inspection items Item See Page Drive Belt Condition 95 Steering System 53 Recoil Rope 51 Parking Brake Lock Brake Lever Brake System 51 52 89 Throttle Lever 50 Throttle Safety Switch 50 Auxiliary Shut Off Switch Engine Stop Switch 55 65 Ignition Switch 55 65 Taillight Brakelight Headlight 55 Coolant Level 84 Gearcase Oil Level N A Engine Oil Level 77 Suspension Mounting Bolts 54 Skags Wear Bars 105
38. abrupt change of direction when operating on slippery sur faces 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 Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and snowmobile rollover causing serious injury or death Use caution and good judgement when driving in hilly terrain Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible rollover 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 parkin
39. al machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury The warranty on your entire machine is terminated if any equipment has been added or any modifications have been made to increase the speed or power of the snowmobile SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures Stay Clear of Engine Never attempt adjustments with the engine running Turn off the igni tion raise the hood make the adjustment secure shields and guards secure the 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 Alwa
40. aler name Date of purchase Details of trouble experienced ON tn BWW Length of time and conditions of operation 7 Previous correspondence 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 116 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 117 WARRANTY Limited Warranty Polaris Sales Inc 2100 Highway 55 Medina MN 55340 provides a ONE YEAR LIM ITED 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 pur
41. ance sprocket teeth bro ken Poor low RPM per Worn drive belt nspect and replace as needed formance SEE YOUR DEALER Loose torque stop Inspect and adjust 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 112 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 tank contains fuel Ice may be in the fuel line filter or pump Add isopropyl alcohol to the fuel system backfires Engine lacks power Fouled or defective Replace the plug s spark plug s Fuel filter loss of SEE YOUR DEALER high RPM power 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
42. ator Low Oil Indicator High Temp Indicator Brake Indicator Reverse Indicator N oO A High Beam Indicator 30 Instrumentation Digital Display Identification FEATURES Item 1 RPM or Speed Altitude i equipped Service Interva 2 Electrical System 3 MAX Maximum MPH KPH or RPM MPH Miles per hour KPH Kilometers per hour RPM Engine crankshaft revolutions per minute 4 Air Temp if equipped Engine Temp Degrees Celsius Degrees Fahrenheit 5 Miles Kilometers 6 Hours Trip 1 Trip 2 Trip F Service Label Altitude Label Voltage Level i ses 31 FEATURES Instrumentation MFD Settings The MFD Control Switch allows you to set the MFD display to your preferences The rocker switch has a MODE button top and a SET but ton bottom Specific instructions are outlined on the following pages Standard vs Metric The MFD will display either standard or metric units of measurement While viewing a screen that displays measurements MPH km h or temperatures press and hold the MODE switch until the unit of mea surement changes about 10 seconds Speedometer Tachometer To change viewing preferences press and hold the MODE button for three seconds When the button is released the new setting becomes active and screen colors change Option Digital Display Screen Backlight e
43. ces is not recommended for models equipped with a deep lug track Track lug damage may occur Keep high speed use to a minimum including frequent slow speed intervals for track cooling 99 MAINTENANCE Track Tension 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 run ning Track tension is critical for maximum efficiency and performance Track tension controls the approach angle of the track to the rail beam in powder snow conditions Deep snow performance will be optimized at the specified tension Looser tensions will cause the track to bunch in front of the rail tips causing improper approach angle and poor perfor mance New tracks will need to be retightened and aligned after the first ride TRACK TENSION DATA CHART Measurement Slack Suspension Weight Location Measurement IQ RMK 10 Ibs 4 54 kg 16 40 cm 3 8 1 2 ahead of rear 1 1 3 cm idler shaft TIP Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 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 Measure at th
44. chase This warranty is transferable to another consumer during the war ranty period through a Polaris dealer Registration At the time of sale 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 set up of your snowmobile is very important in ensuring trouble free operation Purchasing a snowmobile in the crate or without proper dealer set up 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 se
45. d slow speed 8000 high ambient temperatures Check for snow ingestion RPM 10 MPH Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine performance Check for water ice or dirt in the fuel tank or fuel line Loading machines onto trailers Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the machine completely onto the trailer Push and pull it to finish loading if necessary Clutch malfunction Inspect clutch components See your dealer Slow easy clutch engage ment Use fast aggressive throttle to engage clutch 115 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty informa tion contained in this manual Contact your Polaris dealer for replace ment parts service or warranty Your dealer receives frequent updates on changes modifications and tips on snowmobile maintenance which may supersede information 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 following information Serial number Model number De
46. d use extreme caution when operating in unfamiliar terrain continued on next page 24 SAFETY Safety Decals and Locations Operation Warning continued from previous page 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 When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control the vehicle When operating on hard packed snow ice or when crossing roads steering and braking ability are greatly reduced Reduce speed and allow extra space to turn or stop To maintain vehicle control on ice or hard packed surfaces you should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for long periods
47. develops see page 89 bring the snow mobile to an authorized Polaris dealer for inspection and adjustment Brake Pad Material 90 Brakes Brake Fluid 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 rap idly absorbs moisture from the air The moisture causes the boiling tempera ture of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury WARNING Keep the master cylinder cover free of dirt and debris The vent slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function NOTICE Brake fluid will damage decals paint and some plastics Always wipe up spills immediately Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid See page 110 for the part numbers of Polaris products The brake fluid level can be seen through a plastic sight glass in the brake reservoir If the fluid is suf ficient the sight glass will be black If the sight glass is any color other than black add brake fluid 91 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
48. differ from the decals on your snowmobile always read and follow the instructions of the decals on the snowmobile If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Clutch Cover Warning The clutch cover warning decal is under the hood on the clutch cover WARNING Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with plenum belt guard removed Never run engine with drive belt removed Never service clutches yourself See your dealer Pressure Cap Warning The pressure cap warning decal is found under the hood on the pressure cap of applicable liquid cooled models WARNING Do not open hot Test or replace when changing coolant Press down and turn to release cap 13 PSI 22 Safety Decals Locations No Passenger Warning Snowmobiles designed for only a single rider have a warning decal on the console below the steering post WARNING No Passenger This vehicle is designed for Warning operator only NO PASSENGER Track Warning The track warning decal is on the Track rear of the tunnel Warning Hot Surface WARNING Stay clear of track Do not sit seat back Entanglement with the track or a fall from seat back may result in severe injury or death Hot Surface Warning The h
49. e 3 32 FEATURES Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD pro grams Performance Engine and History Each program remains active until you cycle to the next program While any program is active press and release the SET button to cycle through the program s screens Performance Program Press and release the MODE button until the performance program screen is active The default display for this screen includes electrical system voltage fuel level if equipped and either speed or tachometer whichever is selected see page 32 Press and release the SET button to cycle through the following screens odometer trip 1 odometer trip 2 odometer fuel trip odometer if fuel is low and clock if equipped Use the following procedures to make changes to these screens Odometer Setting um The odometer records the vehicle s total distance traveled since manufacture The odometer cannot be reset Trip Settings Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled Both odometers can be reset to zero 1 Enter the Performance Program 2 Press and release the SET button until the desired trip screen is active 3 Press and hold the SET button for two seconds to reset the trip odometer to zero 4 Press and release the SET button to view another trip screen if desired
50. e MFD displays actual air temperature Press and hold the MODE switch for ten sec onds to switch between standard and metric units of measurement Altimeter accessory The rider can calibrate the altimeter for cur rent atmospheric conditions Altimeter accu racy will be 300 ft 91 m after adjustment TIP When ALt FT displays the program is in the FEATURES TIP standard mode If only ALt displays the program is in the metric mode Enter the Engine Program Press and release the SET button until the altimeter screen is active Press and hold the SET button for five seconds When the digits begin to flash release the SET button Press and release the SET button to advance the reading in 50 foot 15 m increments or press and hold the button to advance quickly Adjust the altitude display to within 50 ft 15 m of the current altitude The gauge reads barometric pressure and allows the rider to compensate for daily fluctuations in air pressure The gauge can adjust the displayed altitude to 1300 ft 396 m from the preset value It will adjust up to 1300 ft 396 m above the calibrated altitude Once the 1300 ft 396 m offset has been reached the next adjustment is 1300 ft 396 m from the calibrated altitude and 50 ft 15 m will be added to the altitude each time the SET button is pressed Press the MODE button to hold the reading at the adjusted value If the MODE button is not pressed
51. e point where the weight is placed 4 Check for specified slack between the wear surface of the track clip and the plastic rail slide 100 MAINTENANCE Track Tension Idler Shaft Bolt crew If the track needs adjustment 5 Loosen the rear idler shaft bolt 6 Loosen the lock nuts 7 Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the track 8 Repeat the measurement on the other side of the track TIP Check more frequently when the snowmobile is new 9 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 10 Check track alignment see page 102 and adjust as necessary 11 Tighten the lock nuts 12 Tighten the idler shaft bolts Torque to 35 ft 165 47 5 Nm 101 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 Rail 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 are evenly spaced on each side If the track runs to the left lo
52. e spark plugs every 2000 2500 miles 3200 4000 km 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 Use recommended spark plugs with the proper gap Use only resistor type spark plugs Torque spark plugs to 18 22 ft lbs 24 30 Nm Always carry spare spark plugs Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specification 5 Reinstall the spark plug cap 80 MAINTENANCE Intake Filters The intake foam filter limits snow ingestion into the intake system When operating in loose powder snow check the top of the foam filter periodically to remove any accumulation of snow Intake Foam Filters Pre filter NOTICE Operating the snowmobile with the intake filters removed may cause intake icing The result will be poor fuel economy or intake mal function Always reinstall the intake filters before operating the snowmobile 81 MAINTENANCE Fuel Injectors All fuel injector service must be performed by an authorized Polaris dealer Do not at
53. easurement Y To determine sag commonly referred to as ride in subtract measurement Y from X Sag X Y Adjust sag by rotating the torsion spring preload cams located on the rear torque arm See illustration The ideal amount of sag for this rear suspension is five inches 12 7 cm X Y 5 in 12 7 If the rear suspension rides in less than four inches or more than six inches with the torsion spring preload cams at their maximum range of adjustment optional torsion springs softer or stiffer respectively may be required This is only an initial setup and final spring preload may vary based on rider preference and riding conditions 43 THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload rotate the three position cam using the engine spark plug tool Different rate torsion springs are available if a firmer ride is desired Contact your dealer for more information The following information is provided only as a guideline to be used for initial suspension set up Your set up may vary based on your desired riding style Soft long end of cam to front Medium short end of cam up Firm long end of cam up Ate Sp Medium Firm Limiter Strap Position The following information is pro vided only as a guideline to be used High ee g for initial suspension set up Your set up may vary based on your Low desired riding style High Limiter strap in high
54. ebar Such accessories could limit your ability to steer the vehicle and or may contact the brake lever This could lead to loss of con trol resulting in serious injury or death Always be sure that accessories do not contact the handlebar or brake lever at any handlebar position Handlebar position and handlebar angle can be adjusted to rider prefer ence After making handlebar adjustments check to make sure wires are not pinched or kinked Make sure the handlebars brake lever and throt tle lever operate smoothly and do not hit the gas tank windshield or any other part of the vehicle when the handlebars are turned fully to the left or right When adjustments are complete torque the front adjuster block bolts first then torque the rear bolts Torque the bolts to 11 13 ft Ibs 15 18 Nm 46 THE PERFECT FIT Handlebar Adjustments Handlebar Position 1 Loosen the four bolts on the bottom of the adjuster block If necessary pry the blocks apart with a screwdriver Loosen top bolts to adjust handlebar angle 2 Adjust the handlebar forward E i i or rearward to the desired position 3 Tighten the bolts Handlebar Angle 1 Loosen the four bolts on the qo top of the adjuster block If necessary pry the blocks I 1 12 apart with a screwdriver 2 Adjust the handlebar forward to th 1 Loosen bottom bolts to ELM adjust handlebar position 3 Tighten the bolts 47
55. ement and physical skills WARNING Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Do not allow disabled persons to operate this vehicle Rider Capacity Your Polaris snowmobile is designed for a single rider only Do not carry a passenger 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 trail ahead If your speed is 40 MPH 64 km h your snowmobile is traveling about 60 feet 18 m per second If you look back for only two seconds your snowmobile will travel about 120 feet 36 m If your speed is 60 MPH 96 km h your snowmobile will travel about 180 feet 55 m in two seconds Traveling at night requires extra caution Check headlight and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your snowmobile to a stop in the distance 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 es
56. erage 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 120 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snow mobiles that were Snow Checked through an authorized Polaris dealer during the March April Snow Check promotion The free Second Year Engine Service Contract is honored by all authorized Polaris
57. erating the snowmobile 52 PRE RIDE INSPECTIONS Before Starting the Engine Steering System Manually turn the skis completely to the right and to the left If any dif ficulty is encountered remove any ice and snow build up that may be obstructing the steering linkage Track Inspection WARNING Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle 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 lubri cation would include frozen bodies of water without snow cover icy trails and no snow conditions Track damage or failure caused by oper ation on ice or poor lubrication conditions voids the track warranty Deep Lug Tracks if equipped The 2 4 powder track 1s designed specifically for deep snow applica tions Operation in low snow conditions at high speeds may cause track lug separation Track lug separation is not covered under the Polaris limited warranty policy Polaris does not recommend operation above 70 mph with this track NOTICE High speed use on hard packed surfaces is not recommended for models
58. g Inspection 53 103 Steering System 103 106 Stop 63 StODping s cus p pm em 65 Storage 68 Storage Extended 107 109 129 INDEX Survival Preparation 11 Suspension Adjustments Front 39 41 Suspension Adjustments Rear 42 45 Suspension Inspection 54 Suspension Lubrication Front 75 Suspension Lubrication Rear 75 Suspension Performance Tips 42 Suspension Front 39 Switches 000005 63 T Tether 48 Throttle Lever 50 64 Throttle Safety Switch 50 63 Torque 8 97 Torsion Spring Preload 44 TOWING sed ridet els 68 Track Alignment 102 Track Care for Storage 109 Track Inspection 53 98 Track Lubrication 99 Track Replacement 98 Track Tension 100 101 Track 0 59 Track Waming 23 Track Deep Lug 53 Transporting the Snowmobile 109 Troubleshooting Drive Belt 115 Troubleshooting Engine 111 113 Troubleshooting Rear Suspension 114 130 V Vehicle Identification Numbers 7 W Warning Labels Decals 22 25 Warranty Engine Emissions 123 Windchill Temperature Charts 21
59. g 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 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 Damage to the engine may occur if the intake silencer or filter are removed Clutches Do not attempt to service the clutches All clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is 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 and on 2 up machines with respect for a passenger 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 or a passenger 18 S
60. gine Pull it up to allow restarting Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF Tether Switch If your machine 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 Mirror Adjustment If equipped adjust your mirrors so they can be used to their full advan tage Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile 55 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 Pull the engine stop switch up to the RUN position A CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running 2 If equipped with electric start turn the key to START to crank the engine Release the key to the ON position when the engine starts 3 Ifnot equipped with electric start grasp the starter handle and pull slowly until the recoil engages then pull abruptly to crank the engine TIP Don t pull the starter rope to the fully extended
61. gine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol Polaris also recommends the use of Carbon Clean Plus See page 110 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deic ers or water absorbing additives should not be used 61 OPERATION Oil Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low Visually check for oil in the bottle Add oil before further operation of the snowmobile See page 58 for oil recommendations NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refueling Add oil as needed Low Oil Level Maintaining the proper oil level will prevent system aeration and possi ble loss of pumping action which could result in engine damage This is especially important when the machine is operated in mountainous ter rain Maintain the oil level at the bottom of the filler neck Always check and fill the oil tank when refueling Never operate the engine if oil 1s not vis ible in the tank TIP The Polaris oil cap on the oil bottle is vented to allow proper oil flow See your Polaris dealer for recommended replacement parts 62 OPERATION Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly Pul
62. gine run ning Always allow the engine and exhaust system to cool completely before inspecting 1 Open the hood and inspect the muffler and pipes for cracks or dam age 2 Check for weak or missing retaining springs or damper support grommets 3 Check for loose clamps on the pipe covers 83 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60 40 mixture of ethylene glycol and distilled water This mixture provides protection against freezing Contact your dealer if greater protection is required Use Premium 60 40 anti freeze coolant which is already premixed and ready to use Do not dilute with water Never exceed a 60 antifreeze 40 water mixture See page 110 for the part numbers of Polaris prod ucts TIP 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 or overflow tank Filler neck Pressure cap Connecting hoses Always maintain the coolant level between the minimum and maximum marks on the coolant bottle when engine is cold to prevent overheating and serious engine damage NOTICE Operating the snowmobile with insufficient coolant will result in over heating and serious engine damage Always maintain the coolant level as recommended
63. he adjustment Full Firm range of the spring rate To make Full Soft 7 adjustments turn the large red cap on the reservoir with the aluminum wrench supplied with your vehicle NOTICE To avoid damage use only the supplied wrench to adjust the shock Never use the service port as it may crack and cause a loss Stifter Softer of pressure KA As viewed from the bottom of the cap Turn the cap clockwise for a stiffer C gt ride Turn the cap counterclockwise for a softer ride The shocks are delivered in the full soft position 8th line Each line represents approximately 40 pounds of spring rate at mid stroke on the shock Make Adjustment adjustments in two line increments Wrench maximum as this will have a large effect on the ride of the vehicle 41 THE PERFECT FIT Rear Suspension Adjustments Rider weight riding style trail conditions and vehicle speed all affect suspension action Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions However all sus pension designs and adjustments involve a compromise or trade off For example a suspension set up for snow cross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bot tom out harshly on a snow cross course Make adjustments to one area at a time so you can evaluate the change For further ass
64. he rear sup port is stable 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 of the engine drive train and track 1 Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper The track should be approximately 4 10 cm off the ground e Su lt a Follow these steps to ensure proper warm up 1 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 59 OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel outdoors or in a well ventilated area Always turn off the engine before refueling Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refueli
65. heel Idler Bolts 101 1 l 1 1 I Idler Bolt Jam Nut 101 1 1 l 1 Rear Suspension Pivot 75 L L L Shafts Camber Alignment 1 1 1 Handlebar Centering 1 Tether Switch and Strap 55 1 l 1 1 Track Alignment 102 1 1 1 1 Track Tension 101 l 1 l 1 1 Front Limiter Strap 1 1 1 1 1 Rail Slide Condition 106 1 Chaincase Oil 77 1 1 1 R Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 74 Lubrication Front Suspension The front suspension does not require lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 72 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 75 MAINTENANCE Lubrication Driveshaft Bearing Fitting Inject grease into the fitting on the speed ometer 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 Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as show
66. ill plug making sure it is seated properly gor ANN A 78 MAINTENANCE Spark Plugs 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 A CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection Normal Spark Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service 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 Spark 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 use of non recommended injection oil improper use of the choke or incor rect carburetor throttle body adjustments 79 MAINTENANCE Spark Plugs 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 Change th
67. ines equipped with coolers will result in damage to the cooler or tunnel Always install a track hav ing the lug size recommended for your model Track Inspection WARNING Broken track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and sup port the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire length of each rod Bend the track to check for breakage 4 Replace the track if any rod damage is found 98 MAINTENANCE Track Lubrication A 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 lit tle or no snow for lubrication The slide rail requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty NOTICE High speed use on hard packed surfa
68. into the open threaded access hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves open far enough to remove the belt Sepe 96 Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge on the belt and apply downward pressure while measuring at point A This measurement should be 1 1 4 3 2 cm Drive Belt Adjustment MAINTENANCE Straight Measure Edge 1 Install L wrench into the open threaded hole in the outer sheave of the clutch see page 96 Turn the wrench clockwise slightly to remove pressure from the sheaves 2 Loosen the 7 16 jam nut 3 Usinga 1 8 Allen wrench turn the set screw inward clockwise to increase the distance between the sheaves or outward counterclockwise to decrease the distance 4 Tighten the jam nut Store the L wrench in the tool kit Torque Stop Periodically check torque stop clear ance With clutches in proper align ment measure rear torque stop clearance from the engine case Rear torque stop clearance should be 010 030 25 75mm Adjust 1f neces sary Secure the nut 010 030 25 75 mm 97 MAINTENANCE Track Replacement When replacing the track always install a track having the lug size rec ommended for your model See your Polaris dealer NOTICE Installing tracks with larger lugs on mach
69. ironment Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that snowmobiles conform to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter machines we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly INTRODUCTION Vehicle Identification Numbers Record your snowmobile s identification numbers and key number in the spaces provided below The key number is stamped on the spare key The number on the rubber coated key is in the form of raised dots Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key num ber and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number Tunnel VIN lower right side of the tunnel Engine Serial Number on valve cover
70. istance see your dealer Suspension Performance Tips Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride n deep snow a new rail slide will offer improved performance over worn slide It can also improve top speed TIP Keep the suspension pivot points lubricated This will reduce moisture and rust build up and ensure proper function of the suspension components Grease rear suspension pivots before adjusting the rear suspension Refer to the suspension lubrication information beginning on page 76 42 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting Sag Method To set up the rear suspension torsion spring preload measure the distance between the ground and rear bumper This is measurement X Take this measurement with no rider and with the rear suspension at full extension x 5 TIP The rear bumper may need to be lifted upward slightly to fully extend the suspension Next have the rider drop down hard on the seat and bounce up and down several times collapsing the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact location used for measure ment X This is m
71. itch to OFF 2 Visually inspect the throttle cable and throttle body to determine what caused the safety switch to activate 3 Testthe 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 TIP Excessive freeplay in the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the snowmobile to an authorized Polaris dealer for service If an emergency exists and it s necessary to start the engine the throttle safety switch and engine stop switch may be disconnected from the wire harness When these switches are disconnected the ignition key switch must be used to shut off the engine DO NOT continue to operate the snowmobile with the throttle safety switch disconnected Return the snowmobile to an authorized Polaris dealer for service as soon as possi ble 64 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 63 for more information about the engine stop switch THROTTLE SYSTEM WHAT IT DOES CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft
72. l Damage caused by the failure of other components of the snowmobile Failures caused by improper fuel or oil Piston seizures unless caused by a defective engine component Failures caused due to improper adjustments Failure due to unauthorized service Failures due to lack of service as required in the owner s manual or Polaris updates This includes off season storage as listed in the owner s manual Failure due to use of unauthorized parts or modifications Normal wear parts including but not limited to spark plugs hoses batteries controls and recoil ropes are excluded from coverage Gaskets are covered as are intake and exhaust manifolds excluding paint coverage Electrical coverage is limited to the ECU box coils stator plate and sensors Wiring and other electrical components are excluded from coverage Cooling system coverage is limited to the water pump assembly and components fan fan bearings temperature sensor gasket and seals Non wear related throttle body parts are covered The fuel pump is covered Clutches and related clutch parts including but not limited to the drive belt are excluded from coverage Electrical components are excluded from coverage Gearcases and transmissions are excluded from coverage 121 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 SEL
73. l the switch up to the RUN position to allow restarting Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a throttle system malfunction immedi ately push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer 7 Stop Inc 7 Switch l Test the throttle safety switch system daily before operation Sit on the seat Lock the parking brake Start the engine and allow it to idle Hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration 5 Apply a slight amount of throttle A properly functioning switch must shut down the engine mo por cs 63 OPERATION Throttle Lever WARNING An improperly functioning throttle lever may cause erratic machine 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 sw
74. laris dealer to perform any service that may be necessary for your snow mobile 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 124 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 125 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS KM 126 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 127 INDEX A Accessories 48 Apparel for Riding 12 1 15 B Brake Components 90 Brake 91 Brake Inspection 89 Brake Lever Feel 51 Brake Lever Travel 51 90 Brake System Bleeding 92 Brak
75. mpo nents grease all pivot points elevate front of machine Set static sag see page 43 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Increase IFS preload if equipped see page 41 Move limiter strap to high position see page 44 Steering is heavy Make sure spindles and all steering components turn freely Check ski alignment see page 104 Check skags and skis for damage Set static sag see page 43 Machine darts from side to side Check ski alignment see page 104 Check for binding front suspension shafts steering compo nents grease all pivot points elevate front of machine Check for excessive play in steering assembly see dealer Ensure skags are straight on skis Set static sag see page 43 Check rail slide replace if worn see page 106 Install Accu Trak dual skags see your dealer 114 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear Burn Diagnosis Causes Solutions Driving at low RPM Drive at higher RPM Gear the machine down Check belt deflection Insufficient warm up Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine 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 an
76. ms department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 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 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 Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance see page 116 122 WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris stan dard limited warranty for snowmobiles Polaris Industries Inc warrants that at the time it is first purchased this emissions certi fied snowmobile engine is designed built and equipped so it conforms with U S Envi ronmental Protection
77. n 76 Lubrication Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 71 The sight glass is located on the lower rear of the chaincase Maintain the oil level at or slightly below the center of the sight glass Change the chaincase oil after the first 500 miles 800 km then every 1000 miles 1600 km or seasonally Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 110 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level sur face 2 View the oil level at the sight glass 3 Remove the fill plug and add the recommended oil as needed Do not overfill 4 Reinstall the fill plug making sure it is seated properly MAINTENANCE Sight Glass Maintain Level Here 77 MAINTENANCE Lubrication Chaincase Oil Oil Change 1 Position the vehicle on a level surface 2 Remove the drain plug and drain the oil into a drain pan Allow the oil to drain completely 3 Clean off all metal shavings from the plug 4 Install a new sealing washer on the we drain plug The sealing surfaces on the Drain Plug drain plug and the oil tank should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 6 10 ft Ibs 8 13 Nm Remove the fill plug Clean off all metal shavings from the plug Add 11 oz 325 ml of the recommended oil Do not overfill Reinstall the f
78. ne damage can occur without the proper lubrication Check the oil tank level often during the first tank of fuel If the oil level doesn t go down contact your dealer immediately Oil Recommendations This snowmobile is equipped with a variable exhaust system VES Engine lubrication comes from oil added to the fuel and oil injection systems Polaris recommends the use of VES II 2 Cycle Oil for this engine See page 110 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 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 Track Warm Up WARNING A loose track or flying debris could cause serious injury or death Stand clear of the front of the machine and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throt tle during warm up or when the track is free hanging Be sure t
79. ng is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 60 OPERATION Fuel For peak performance Polaris recommends the use of 91 octane or higher fuel Although 87 octane fuel is usable some engine perfor mance will be lost and fuel economy will decrease Do not use lower than 87 octane fuel Do not use fuel containing more than 10 ethanol including E85 NOTICE Operating with obstructed fuel systems will result in serious engine damage Perform maintenance as recommended Damage to the fuel pump will occur if the snowmobile is operated with an empty fuel tank Do not allow the snowmobile to run out of fuel Always refuel when the level is low Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel Fuel System Deicers If you use non oxygenated fuel 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 en
80. o 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 150 mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CLUTCH Clutch Alignment Offset 94 1 1 1 without belt Drive Belt Condition 95 1 1 1 I Clutches disassemble 94 C Belt Tension 1 1 1 I Clutch Sheaves 94 1 1 1 ENGINE COOLING Engine Mounts 1 1 1 Recoil Rope 1 l 1 1 Engine Torque Stop 97 1 1 1 I Oylinder Head Bolts 1 l 1 Cylinder Base Nuts 1 1 1 1 Ignition Timing BTDC 1 1 1 VES System Cc C 1 Coolant Level 84 1 1 R Coolant Hose 1 1 1 Heat Exchangers 87 l 1 1 1 Coolant Circulation 1 1 1 Coolant Leaks 1 1 1 Spark Plug Condition 79 l 1 R 1 Exhaust Pipe 83 1 Exhaust Retaining 83 1 1 1 Springs Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 72 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page i50 mi 500 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season BRAKES Hose Routing 1 1 1 Hose Condition 1 1 1 Fluid
81. oblems 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 of spec Engine mount bro ken or loose Harsh drive clutch Drive belt worn or Replace the drive belt engagement too narrow Excessive belt SEE YOUR DEALER sheave clearance Drive belt turns over Wrong belt for appli Replace the drive belt cation Clutch alignment out 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 111 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive sys tem Broken drive clutch components SEE YOUR DEALER Bearing failure chaincase jackshaft or front drive shaft SEE YOUR DEALER Drive belt surface flat spots Inspect and replace as needed Drive chain loose Inspect and adjust or replace Drive chain worn SEE YOUR DEALER Excessive belt sheave clear
82. of any dealer to perform the required vehicle Pre Delivery Inspection perform all applicable service bulletins and have the consumer 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 during 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 from warranty cov
83. or Safety Windchill Temperature Charts The following information is provided to help you determine when tem peratures become dangerous for riding WIND CHILL CHART F SAFETY WIND CHILL CHART C Wind Actual Thermometer Reading F 40 35 30 25 20 15 10 5 0 5 101 15 20 25 30 85 40 45 Equivalent Temperature F 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 5 36 31 25 19 18 1 5 11 16 22 28 34 40 46 52 57 63 34 27 21 15 9 8 4 10 16 22 28 35 41 47 58 59 66 72 15 32 25 19 13 6 0 7 13 19 26 32 39 45 51 58 64 20 30 24 17 11 4 2 9 15 22 29 35 42 48 55 61 25 29 23 16 8 8 4 11 17 24 81 37 44 51 58 30 28 22 15 8 1 5 12 19 26 33 89 46 58 35 28 21 14 7 0 7 14 21 27 84 41 48 40 27 20 13 6 1 8 15 22 29 86 43 50 45 26 19 12 5 2 9 16 23 30 87 44 50 26 19 12 4 3 10 17 24 31 88 45 4 11 18 60 25 17 10 3 4 11 19 26 33 40 Frostbite in gt gt 30 min 10 min
84. osen the left locknut and tighten the left adjusting bolt If the track runs to the right loosen the right locknut and tighten the right adjusting bolt 4 After adjustments are complete tighten the locknuts and torque idler shaft bolts to 35 ft lbs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment 102 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners TAN 12 P c 1 A 103 MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski align ment 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 8 to 1 4 3 6 mm greater than the measurement at point Y If the skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may also be affected 10 in 25 4 cm 10 in 25 4 cm 104 MAINTENANCE Steering System Ski Skags WARNING Worn ski
85. ot surface warning is on the rear center of the tunnel WARNING Hot Surface Do Not Touch Burns may result Entire top of tunnel may be hot Install only accessories specifically approved for this model by Polaris Do not place clothing bags or cargo on tunnel Do not cover this label 23 SAFETY Safety Decals and Locations Reverse Warning Polaris snowmobiles equipped with electric reverse have a reverse warning decal on the console WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Reverse Warning Shift to or from reverse only when stopped Apply throttle slowly Operation Warning 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 Operation Warning The operation warning decal is located on the console of all Polaris snowmobiles 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 an
86. otes 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 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 env
87. pecially 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 Avoid travelling on frozen bodies of water 14 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain Take an avalanche class Travel with experienced people E 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 info
88. position increases ski pressure Low Limiter strap in low position decreases ski pressure 44 THE PERFECT FIT Rear Suspension Adjustments Shock Compression Valving Standard Rear Track Shock The standard RMK rear track shock is an Arvin MPV Select shock that allows for adjustments to the compression valving Adjustments made by turning the adjustment screw located near the base of the shock In half turn increments Turn the screw clockwise for a stiffer ride Turn the screw counterclockwise for a softer ride If bottoming continues after the screw has been turned fully clockwise the torsion w Stiffer Softer E spring should be adjusted see page 44 Return the screw to its original starting 7 position after the torsion spring has been adjusted Assault Rear Track Shock Turn the adjustment knob on the shock reservoir to make adjustments to the com IL pression damping When adjusting we recommend that you turn the adjuster slightly then test ride Turn the knob clockwise for a stiffer ride Turn the knob counterclockwise for a softer ride Stiffer Sof RKA 45 THE PERFECT FIT Handlebar Adjustments WARNING Some aftermarket accessories including windshields and cargo bags may interfere with the handl
89. r dealer as the camber adjustment may also be affected Air Shocks Walker Evans air shocks can be adjusted for preload and valving Please see your Polaris dealer for these adjustments Standard Shocks The tension at which the shock coil spring is set is called spring preload For the best ride the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming To determine if your machine is using full travel push the jounce bumper down on the shock rod until it contacts the body and test ride the machine The bumper will move up on the rod in relation to the amount of travel that was used dur ing the ride If the travel is full the bumper will be seated at the top of the rod Shock Absorber Components 1 Retainer 2 Jounce Bumper 3 Shock Rod 4 Body 5 Threaded Spring Preload Adjuster Nut 6 Spring Standard only 40 THE PERFECT FIT IQ Front Suspension Adjustments Front Shock Springs Standard Only The front springs can be changed if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness See your Polaris dealer for more information Front Shock Spring Rate Assault Model The Assault IFS shocks are equipped with an adjustable spring cote feature This adjustment will not affect the pre load ride height of the vehicle There are eight lines scribed in the body of the reservoir that represent t
90. r 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 tobog gan or sled make sure the pole is at least four feet 1 2 meters long to pre vent any possibility of contact between the snowmobile s track and a person riding in the towed object Braking distances increase when towing loads Slow down to maintain con trol of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damage to the steering components Remove the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary NOTICE Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 68 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
91. riven clutch counterclockwise to move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut 3 Finger tighten the adjuster bolt until it can no longer be adjusted by hand then back off 1 4 turn 4 Tighten the jam nut while holding the adjuster bolt Torque to 21 ft Ibs 28 Nm 5 Release the brake lever lock 88 Brakes Hydraulic Brake Inspection Inspect the brake lever travel 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 16 1 5mm A kit is avail able for replacing brake pads See your dealer WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 1 5mm 89 MAINTENANCE Brakes Brake Components Brake Disc Bleed Screw Bleed Screw Brake Disc Brake Line Brake Line Brake Caliper Brake Pad Material Replace when thickness is less than 1 16 1 5mm Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance
92. rmance Always carry a spare belt in case of an emergency For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile Drive Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack TIP To ensure satisfactory belt life install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt removal procedures 2 Rotate the L wrench counter clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the wrench and store it in the tool kit Reinstall the side panel 5 Close and secure the hood 95 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 1 Stop the engine after operating in a forward motion TIP For easier accessibility make sure the clutch tool access hole is visible between the 11 00 and 2 00 positions of the clutch sheave 2 Turn the ignition key off Wait for the engine to come to a complete stop Access Hole Lock the parking brake Open the hood Remove the left side panel Locate the L wrench in the tool kit Install the wrench
93. rmation 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 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 A 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 16 SAFETY Operator Safety Driving on Slippery Surfaces WARNING Never attempt an
94. rs or protective rubber boot Do not spray the back side of the gauge or the wire harness with a pressure washer or other water source NOTICE To prevent damage to the lens do not use alcohol for cleaning Do not allow chemicals or sprays to contact the lens Immediately clean off any gasoline that splashes on the gauge during refueling 38 THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension IFS Break in the suspension for approximately 150 miles 240 km before making any fine tuning adjustments Settings will vary from rider to rider depending on rider weight vehicle speed riding style and trail conditions We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The snowmobile should be methodically tested one change at a time under the same conditions trail and snow condi tions vehicle speed riding position etc after each adjustment until the best ride is achieved IFS Components 1 Ski 2 Front shock and spring 3 Rod ends 4 Upper control arms 5 Lower control arms IFS Adjustment Options Shock spring preload Shock valving Optional springs Toe ski alignment see page 104 Camber see your dealer 39 THE PERFECT FIT IQ Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS See page 104 to check alignment If the skis are misaligned see you
95. rvice or parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material 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 REM EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLI GENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclu sion 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 118 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 RANTIES NOT STAT
96. s 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 Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement Some models are equipped with single skags Other models are equipped with dual skags 1 Raise and support the front of the snowmobile so the skis are approximately 6 15 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse the steps to install a a skag Skag 105 MAINTENANCE Steering System Rail Slide Wear For ease of inspection all Polaris rail slides have a wear limit indicator groove to indicate the minimum permissible slide thick ness 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 in permanent damage to the track or rails 106 Minimum Thickness Replace when
97. s 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 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 NOTICE If the brake lever is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly The lock will return to the unlocked position A 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 op
98. s operated See page 63 for procedure Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions Under no circumstances should your snowmobile be operated with the hood open or removed Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmo bile 50 PRE RIDE INSPECTIONS Before Starting the Engine Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear is found see your Polaris dealer for replacement 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 4 2 1 3 handgrip than 1 2 1 3 cm 21018167 A smaller distance indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 92 Brake Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 91 Check for the presence of air in the fluid system See page 92 for more information or see your dealer for service WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Alway
99. tempt to clean or service the fuel injectors Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer Do not attempt to service the fuel pump Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 72 Fuel Lines 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 Oil Lines Inspect oil line condition at the intervals outlined in the Periodic Main tenance Table beginning on page 72 Oil Filter Have your dealer change the oil filter and bleed the system at the intervals outlined in the Periodic Maintenance Table beginning on page 72 TIP The direction of the arrows indicates the direction of flow through the filter 82 Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 71 A CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the en
100. wmobile until repairs have been made All clutch maintenance and repairs must be performed by an authorized Polaris dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty NOTICE The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum perfor mance Please see your Polaris dealer if you experience a decrease in performance Clutch Center Distance See your Owner s Manual Supplement for recommended center distance for your machine If adjustment is necessary see your dealer 94 Clutch System Drive Belt Condition Belt width and length must match the center distance of the clutches and sheave width of the drive clutch For this reason Polaris recommends that only O E M belts be used Other belts may match the dimensions but can drastically change the shift pattern resulting in poor perfor mance See Drive Belt Troubleshooting on page 115 Periodically check the condition and tension of the drive belt and always carry a spare 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 TIP A worn belt will continue to function but will not deliver maximum perfo
101. worn to top of groove MAINTENANCE 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 110 for the part numbers of Polaris prod ucts Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously 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 Controls and Linkage Lubricate all bushings spindle shafts tie rod ends and cables as outlined in the Periodic Maintenance Table beginning on page 72 Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All Season Grease or a similar high quality grease to prevent corrosion 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 107 MAINTENANCE Extended Storage Engine Protection
102. ys stop the engine before attempting adjustments 10 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience but under many conditions the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle brake and steering control WARNING Improper riding position may reduce control and could result in serious injury or death Always ride in a position that allows for control of your vehicle 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 11 SAFETY Operator Safety

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