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Polaris 600 IQ Widetrak Offroad Vehicle User Manual

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1. 44 THE PERFECT FIT Rear Suspension Adjustments Rear Shocks ARVIN Rapid Adjust Shock The ARVIN Rapid Adjust shock is available as an option on some models Turn the Rapid Adjust knob on the shock reservoir to make adjustments to the compression damping Positions are labeled on the shock When adjusting we recommend that you turn the adjuster slightly then test ride a itt ET IJ 45 THE PERFECT FIT Handlebar Adjustments Handlebar Position Use the RIDER SELECT feature to adjust handlebar position See page 26 Handlebar Angle Follow these steps to adjust handlebar angle at the handlebar block 1 Remove the handlebar cover 1 to expose the handlebar and the four adjuster block bolts 2 NOTE f necessary remove the mountain bar 3 2 Using a 7 16 11 mm wrench loosen the four nuts 3 on the bottom of the adjuster block turn handlebar to left or right for access to back nuts NOTE f necessary pry the blocks apart with a screwdriver 3 Adjust the handlebar to the desired height Be sure handlebars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine w
2. 109 Warranty auibus 114 Maintenance Log 120 INGOX eA 122 INTRODUCTION Important Notes for Owners and Drivers After reading this manual store it in the snowmobile for convenient reference It should remain with the snowmobile when sold Some of the illustrations and photos used in this manual are general representations Your model may differ Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding clubs INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education campaign We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment including wildlife and vegetation Snowmobile clubs and other organizations are working together to protect our environment Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment Noise Level One of the most publicized issues about snowmobiles is noise The
3. 81 Fall 96 FEATURES 25 38 Flushing the Cooling System 85 Front Shock Spring Preload 40 Front Springs 40 Fuel are RETE 61 62 Fuel Filter ice 80 Fuel Level 62 Fuel Limes so a Ss 80 Fuel Pump 80 Fuel System Deicers 62 Fuel Valve hie be e a eigen eet 28 G Gauge Cleaning 38 General Maintenance 81 96 H Halogen Bulbs 91 Handlebar Adjustments 46 Handlebar Angle 46 Handlebar Position 46 Headlights 28 High Temperature Indicator 85 Hydraulic Brake Inspection 88 Ice and Snow Build up 15 TES sone e ehe nS 39 IFS Components 39 Instrumentation 30 38 Intake Filters 80 Intake Silencer 17 INTRODUCTION 5 7 L Lighting Check 56 Low Oil Indicator 63 Low 1 63 Lubrication 74 77 M MAINTENANCE 70 107 Maintenance Interval Table 71 73 MAINTENANCE LOG 120 121 Maneuverability 17 MED Battery Replacement 37 MFD Component Identification 30 MED Digital Display Programs 32 36
4. 55 97 Track Lubrication 97 Track Maintenance 97 100 Track Safety 10 Track Tension 98 99 Track Tension Data 99 Track Warm Up 60 Traction Products SwitchBack 48 49 Transporting the Snowmobile 107 TROUBLESHOOTING 109 112 124 V Vehicle Identification Numbers 7 Warning Labels 21 24 WARRANTY 114 119 Wear Strips 49 WELCOME 1 Windchill Temperature Charts 20
5. 1 vr j m Water Pump Drive Bet 1 v poosantdos a pede pas Heat Exchangers or ovr vg Coolant Circulation 1 or vr y CoolantLeaks ___ _ 1 vr Spark Plug Condition 9 v v v vr Exhaust Pipe __ 85 rr Exhaust Retaining 81 Springs Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 71 MAINTENANCE Periodic Maintenance Interval Table See Frequency Page isomi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season Brakes Jo f poo L IL second fo Pamoa fa 9498 Basme o Tr Fuel Management stones Oil Pump Lever Imemecae 75 o me e veris T SL EO Fame fo Ja 1 8 1 Foams fa __ 1 5 1 omms seek po p 5 T 1 3 4 Satay swin o6 1 41 1 Tomon wich 1 4 11 Bam 5 3 123 mew 12 12 14 eda 5 1 13 1 72 MAINTENANCE Periodic Maintenance Inter
6. Locate the black battery compartment 1 It has a red wire and a brown wire with a white stripe It s located about three inches down the main harness from the point where the harness connects to the MFD Cut the plastic cable tie 2 from the outside of the compartment Carefully cut the bottom of the compartment opposite the wires to separate the heat sealed seams Squeeze the corners of the compartment inward so the battery 3 is visible NOTE Note the orientation of the battery before removing it An 5 incorrectly installed battery will not maintain the clock Using needle nose pliers grasp the battery and rotate it slightly so the leading edge of the battery is raised slightly away from the battery holder Pull the battery out gently NOTE The battery will not come out of the holder unless the leading edge of the battery is raised Hold the battery compartment not the wires while removing the battery Pulling on the wires will separate them from the battery holder Install a new battery with fingers only Seal the end of the battery compartment using high strength double sided tape between the two compartment halves or high strength single sided tape around the outside of the compartment Make sure the taped seam of the compartment faces the downward side of the wire harness Install a cable tie to secure the compartment to the wire harness in the same location where the previous cable tie was located
7. 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 recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 116 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 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 re quired 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
8. Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience 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 4 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 10 SAFETY Operator Safety Survival Preparation For your safety always ride in a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the conditions you may encounter Such equipment may include but is not limited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cellular telephone For added protection carry the following items on your snowmobile at all times eSpare Drive Belt Extra Set of Spark Plugs Tow Rope Extra Oil Fuel Deicer Winter Survival Kit rail Map Owner s Manual First Aid Kit Tool Kit Riding Apparel Be prepar
9. Settings 31 Mirror Adjustment 56 oat Seats ep IRE 63 Qil Filter zi seas 81 Oil Injection System 59 OIFLINES RARE 81 Oil Recommendations 59 OPERATION 57 69 Operations sags see eem gees 24 Operator Safety 8 20 Passenger 22 vem De RR ute 68 POLARIS PRODUCTS 108 Pre Ride Checklist 50 PRE RIDE INSPECTIONS 50 56 Pre Ride Suspension Inspection 104 Pressure Cap irse REIS 21 R Rack Cargo 28 Radiator Compartment Access 28 Rail Slide eH 104 Recommended Maintenance Program 70 Reverse Ier 23 68 Rider Capacity 12 RIDERSELECT 26 27 Riding Apparel 11 Riding Position 10 S ayesan wae eign ote 8 24 Safety Decals and Locations 21 24 Sag osa ete RAT RUP es 42 Seat Storage Compartment 28 Second Year Engine Service Contract 118 Service And Warranty Information 114 Shock 40 Shock Rapid Adjust ARVIN 45 Shock Rear Indy Select 44 Shocks 44 45 Signal words 8 Skag 103 Skags vv Sse APO 49 Ski 102 SkrSkags s mg 103 Slide Ra
10. 29 FEATURES Instrumentation MFD Component Identification Rm ema BLESE Altitude if equipped Service Interval RPM or Speed Level 3 MAX Maximum MPH KPH or RPM MPH Miles per hour KPH Kilometers per hour RPM Engine crankshaft revolutions per minute Electrical System Voltage Air Temp if equipped Engine Temp Degrees Celsius Degrees Fahrenheit 5 Miles Kilometers Hours Trip 1 Trip 2 Trip F Service Label Altitude Label Fuel Level 7 30 AIR ENG C F FEATURES Instrumentation MFD Settings With the engine running use the CEN MFD Control Switch 1 to set the 1 display to your preference CD The rocker switch has a MODE orion 3 button 2 and a SET button 3 Standard vs Metric ID The MFD will display either standard or metric units of measurement While viewing a 2 3 screen that displays measurements MPH KPH or temperatures press and hold the MODE switch until the unit of measurement changes about 10 seconds Speedometer Tachometer The speedometer and tachometer can be viewed in either the analog or the digital display If the analog display is set to show speedometer readings the digital screen will automatically display the tachometer option 1 If the analog is set to show the tachometer the digital screen will show the speedometer option 2 To change preferences
11. All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury The warranty on your entire machine is terminated if any equipment has been added or any modifications have been made to increase the speed or power of the snowmobile SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation 4 WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures Stay Clear of Engine Never attempt adjustments with the engine running Turn off the ignition raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation 4 WARNING
12. POLARIS The Way Out 2006 Owner s Manual for Maintenance and Safety 600 RMK 600 SwitchBack For your nearest Polaris dealer C POLARIS 5 REE ye Qut or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part 9920058 Rev 02 Printed in USA A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm onto the snow on which they operate Keep this engine properly tuned and avoid unnecessary idling and spillage during fueling A WARNING The engine exhaust from this product contains chemicals known 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 recreational vehicles manufactured in the world today
13. 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 1 Tum screw clockwise to stiffen compression Standard 2a Limiter strap in high position increases ski pressure 2b Limiter strap in low position decreases ski pressure 3a Turn the knob to the left for a softer ride Premium 3b Turn the knob to the right for a stiffer ride Premium 4a Soft Tension long end of cam to front 4b Medium tension short end of cam up 4c Firm tension long end of cam up 43 THE PERFECT FIT Rear Suspension Adjustments Rear Shocks Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock Locate the adjustment screw near the base of the shock In half turn increments turn the screw clockwise to increase compression valving and stiffen the ride or counterclockwise to reduce compression and soften the ride There are approximately three full turns of adjustment available If bottoming continues after the screw has been turned fully clockwise the torsion spring should be adjusted see page 43 Return the screw to its original starting position after the torsion spring has been adjusted
14. Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and support the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire length of each rod X Bend the track to check for breakage 4 Replace the track if any rod damage is found Track Lubrication 4 WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication 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 NOTE Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty CAUTION High speed use on hardpacked surfaces 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 97 MAINTENANCE Track Maintenance WARNING Moving parts can cut and crush body parts When performing the checks and adjustments r
15. This can result in decreased engine RPM and performance The engine is designed to provide maximum power when premium 91 octane fuel is used If a lower octane fuel is used or if the jetting is incorrect for your altitude the DET system will retard ignition to prevent detonation When the DET system is adjusting the timing the DET light on the gauge will flash In most cases the flashing will be temporary and the timing will return to normal If there is intermittent flashing it s likely that the fuel or jetting is incorrect In extreme conditions the DET system retards timing and holds it in a retarded state The DET light will remain on until the engine is turned off and restarted DET Troubleshooting Use this chart to determine causes and solutions for detonation If none of these conditions exists and the sensor remains activated see your Polaris dealer for diagnosis Possible Cause Solution Poor quality fuel Replace with higher quality fuel Improper engine modifications Do not modify the engine Improper jetting Use the correct jetting for your altitude 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 NOTE The DET light will flash six times if the sensor fails or becomes disconnected
16. 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 machine to maintain proper balance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you re unable to continue up a hill turn the machine 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 machine pull the rear of the snowmobile around and point the front end and skis downhill Remount the machine restart the engine release the parking brake and descend the hill carefully 16 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 clutch service must be performed by your d
17. obstructing the steering linkage NOTE f your snowmobile is equipped with RIDER SELECT perform this check in both the full up and full down steering positions Driving on Slippery Surfaces 4 WARNING Never attempt an abrupt change of direction when operating on slippery surfaces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces steering and braking control which may result in loss of control and serious injury or death Slow down and use extra caution when operating on slippery surfaces Driving Downhill When riding downhill shift your weight to the rear of the machine 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 machine and keep it from rolling freely downhill 4 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 15 SAFETY Operator Safety Driving in Hilly Terrain 4 WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll over causing serious injury or death Use caution and good judgement when driving in hilly terrain
18. 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 dam aged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 117 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles 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 snowmobile dealers in North America and is transferable 120 days after the original purchase date free of charge through any Polaris snowmobile 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 registration 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 eligi
19. the more studs you use the longer the carbide on the skags should be See your dealer s track studding chart Wear Strips To avoid excessive tunnel wear tunnel wear strips must be installed whenever track studding is used Install Wear Strip Kit P N 2875415 Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction accessories CAUTION Whenever wear strips are relocated be sure there s adequate stud clearance to the heat exchangers Lack of clearance may result in damage to heat exchangers 49 PRE RIDE INSPECTIONS Pre Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile Procedures are outlined on the referenced pages Look for a checkmark on the referenced pages to locate the pre ride inspection items eee eo eU ee 78888 Drive Belt Condition Steering System Recall Rope Coolant Level Ignition Switch Taillight Brakelight Headlight Suspension Mounting Bolts Skags Wear Bars Ski Saddle and Spindle Bolts Hood Straps Latches Seat Latches Throttle Lever Safety Switch 51 64 65 Rear Wheel Idler Bolts Tether Switch Strap Track Alignment Condition Rail Slide Condition Chaincase Oil Level Injection Oil Level 50 PRE RIDE INSPECTIONS Before Starting the Engine 4 WARNING Worn damaged or malfunctioning components may cause serious injury or death Before starting the engin
20. the snowmobile will be able to climb up and over the snow 4 amp CAUTION When operating on icy surfaces or hard packed snow avoid overheating the slide rail and track Lack of lubrication and cooling will cause overheating of the slide rail and track resulting in premature wear and failure If frequently operating in low cooling conditions see your dealer for an optional wheel kit that will reduce the wear from overheating 18 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently and even the most docile conditions may become dangerous if operators drive improperly If you re new to snowmobiling acquaint yourself with the machine and with what it will and won t do under various conditions Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers e A snowmobile depends on the rider s body position for proper bal ance in executing turns traversing hills etc Always start on a smooth level area to begin building your operating experience Before allowing someone else use your snowmobile know the ex tent of their operating skills Check to see if they ve taken a snow mobile safety course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safe ty course Everyone can benefit from the course Don t jump your snowmobile Jumping may injure your back be cause of spinal compr
21. trained and equipped before traveling in mountainous terrain Take an avalanche class Travel with experienced people Travel on designated trails Make sure each person is equipped with a shovel probe and avalanche beacon You don t have to be snowmobiling on a slope for an avalanche to occur Be aware that all of the snow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in mountainous terrain Before riding in mountainous terrain call or log on to your local avalanche advisory to get current weather and snow stability information For more information about avalanche training and avalanche conditions contact local law enforcement in your area or visit either the American Avalanche Association online at www americanavalancheassociation org or the U S Forest Service National Avalanche Center at www avalanche org 14 SAFETY Operator Safety Ice and Snow Build up 4 WARNING Ice and snow build up may interfere with the steering of your machine 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
22. 0 MEM 50 19 I2 4 3 10 7 2 31 MM 4 S 5 MM 5o 15 17 10 3 4 15 26 Posten Somn EM Actual Thermometer Reading pre eee Equivalent Temperature 88 18 20 24 29 33 96 3 8 2 6 21 25 29 Frostbite in gt gt 30 min 10min 20 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protection Read and follow the instructions of the decals and other warnings on the snowmobile carefully If any of the decals depicted in this manual 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 This warning decal is found under the hood on the clutch cover A WARNING AVERTISSEMENT Do not operate engine with Ne faites pas fonctionner moteur lorsque le hood open capot est ouvert Do not attempt adjustment N effectuez aucun ajustement lorsque le with engine running moteur est en marche Do not operate engine with Ne faites pas marcher le moteur avec le plenum belt guard removed plenum garde courroie retir Never run engine with drive Ne laissez
23. 57 Make sure the fuel tank contains fuel Ice may be in the fuel line filter or pump Add isopropyl alcohol to the fuel system Poor engine Mixture is too lean This indicates a ma compression jor engine problem that must be repaired before the engine is run SEE YOUR DEALER Fouled or defective Replace the plug spark plug Fuel filter loss of SEE YOUR DEALER high RPM power Incorrect clutching SEE YOUR DEALER Faulty plug s Change plug s Fuel System e Dirt or ice may be in the fuel system deicer should be added to non ethanol fuel at all times for assurance against fuel line icing Incorrect throttle free SEE YOUR DEALER play or faulty switch Poor gasoline or not Replace with fresh winter fuel enough fuel getting to engine Spark plug wires may Reinstall spark plug wires to the corre be on wrong cylinder sponding cylinder 111 TROUBLESHOOTING Suspension Troubleshooting Problem Rear suspension bottoms too easily Rear suspension rides too stiff Too much weight transfer when climbing Too little weight transfer when climbing Front end pushes Steering is heavy Machine darts from side to side 112 Solution perform only one change at a time Verify sag dimension see page 42 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Increase shock compression damping see page 44 Check for binding
24. Broken drive clutch SEE YOUR DEALER system components Bearing failure SEE YOUR DEALER chaincase jackshaft or front drive shaft Drive belt surface flat Inspect and replace as needed spots Drive chain loose Inspect and adjust or replace Drive chain worn SEE YOUR DEALER sprocket teeth broken Poorlow RPM Worn drive belt Inspect and replace as needed performance Excessive belt sheave SEE YOUR DEALER clearance Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Poor fuel quality Use 87 91 octane fuel or higher Engine doesn t Seized engine SEE YOUR DEALER Seizure is a re turn sult of poor lubrication inadequate fuel supply broken parts or improper cool ing 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 lo cated on the lower crankcase for emer gency draining 110 TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Engine lacks power Engine continually backfires Engine requires more than normal pulls to start Engine back fires but fails to start Probable Cause Solution Faulty ignition e Install new spark plug s If engine still fails to start check for spark If there s no spark SEE YOUR DEALER No fuel to engine Make sure the fuel valve is on Use the choke See page
25. Cleaning and Preservation 105 Clutch Alignment 92 Clutch and Drive System 106 Clutch Center Distance 92 Clutch 21 Clutch System 92 17 Cold Weather Drive Away 17 Controls and Linkage 105 ER mec REY 84 Coolant 1 84 D Daily Storage 69 Detonation Elimination Technology 29 Digital Display Identification 30 Disabled Operators 12 Drive Movie ete 17 Drive Belt Adjustment 95 Drive Belt Condition 93 122 D Drive Belt Deflection 95 Drive Belt Installation 94 Drive Belt Removal 93 Drive Belt Troubleshooting 113 Drive Chain Tension 87 Driver Awareness 13 Driveshaft Bearing 75 Driving Downhill 15 Driving in Hilly Terrain 16 Driving on Slippery Surfaces 15 Driving Responsibly 19 E Electrical Connections 107 Electronic Reverse 68 Emergency Starting 67 Emergency Stopping 66 Engine Break In 58 Engine Protection 106 Engine Safety 10 Engine Stop Switch 56 64 Engine Troubleshooting 109 111 Excessive Speed 12 Exhaust System
26. Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our complete line of apparel parts and accessories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc RIDER SELECT is a trademark of Polaris Industries Inc Copyright 2005 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedu
27. Remove the attaching nuts and pry the skag downward 3 Remove the forward portion of the skag Reverse this procedure for new skag installation 103 MAINTENANCE Steering System Rail Slide Measure slide thickness at several points along the 7 16 rail Have your dealer 1 1 cm replace the slide when it s worn down to the top of P il the wear groove Do not operate the snowmobile if slide thickness measures less than 7 16 1 1 cm Suspension Maintenance Pre Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile s reliability and cause needless repairs and down time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the following items on a weekly basis or before any long trip Check suspension mounting bolts for tightness Check rear idler wheel bolts for tightness See page 99 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter strap condition Check slide rail condition See page 104 Check track tension See page 99 Lubricate all rear suspension components See page 74 Check ski runner skag condition Check ski spindle bolts for tightness NN N NN ANN YY Y Check tie rod end nuts for tightness 104 MAINTENANCE Suspension Maintenance Extended Storage Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration a
28. adjust the handlebar position to fit your style of riding Choosing the Best RIDER SELECT Position Relaxed Trail Riding Rider weight is slightly behind the center of the snowmobile for comfortable and re laxed riding General Trail Riding Boondocking Deep Snow Riding Rider weight is centered on the snowmo bile providing balance comfort and con trol for both novice and experienced rid ers This is the recommended position for most riding situations Snowcross amp Steep Hill Climbing Only Rider weight is slightly ahead ofthe center of the snowmobile adding weight to the Skis and making the snowmobile feel heavier at the front These positions are desirable for hill climbing and may reduce maneuverability for other types of riding 26 FEATURES RIDER SELECT Adjustable Steering System WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death Always stop the snowmobile before attempting to adjust the steering system 1 Stop the snowmobile Press the release button and move the handlebar forward or rearward to the desired position 4 WARNING Do not lubricate the RIDER SELECT mechanism Doing so could cause loss of control and result in serious injury or death a RIDER SELECT mechanism is lubricated for life at the actory 4 WARNING Some aftermarket accessories including windshields and cargo bags ma
29. 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 ex cluded from coverage Electrical components are excluded from coverage e Gearcases and transmissions are excluded from coverage 118 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris 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 Warran
30. ft Ibs 47 5 Nm Track Tension Data Measurement Measurement Location 16 ahead of rear 3 8 1 2 IQ RMK 10 Ibs 4 54 kg idler shaft 1 1 3 cm IO SwitchBack 10 Ibs 4 54 kg 16 E ORUM d 3 joan 99 MAINTENANCE Track Maintenance Track Alignment Periodically check that the track is centered and running evenly on the slide rails Misalignment will cause excessive wear to the track and slide rail 1 Safely support the rear of the machine with the track off the ground 2 Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails X are evenly spaced on each side If the track runs to the left loosen left locknut and tighten the left adjusting bolt If the track runs to the right loosen right locknut and tighten the right adjusting bolt 4 After adjustments are complete tighten locknuts and torque idler shaft bolts to 35 ft Ibs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment 100 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary 101 MAINTENANCE Steering System Ski Alignment 4 WARNING Improper ski alignment or adjustment may cause loss
31. if equipped The MFD displays actual air temperature Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement 33 FEATURES Instrumentation MFD Digital Display Programs Altitude if equipped The rider can calibrate the altimeter for current atmospheric conditions Altimeter accuracy will be 300 ft 91 m after adjustment NOTE Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement When ALt displays the program is in the metric mode 1 Enter the Engine Program and select the altimeter display Press and hold the SET button for five seconds 3 When the digits begin to flash press the SET button once to advance 50 feet 15 m or press and hold the button to advance 100 ft 30 m every 0 1 seconds Adjust the altitude display to within 50 ft 15 m of current altitude NOTE 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 4 Press the MODE button to hold the reading at the adjuste
32. jamais le moteur en marche lorsque belt removed la courroie d entra nement est Never service clutches Ne r parez jamais l embrayage vous m me yourself see your dealer voir votre concessionnaire 7172672 Pressure Cap Warning This warning decal is found under the hood on the pressure cap of applicable liquid cooled models Warming Do not open hot Test or replace when changing coolant Press down and turn to release cap 13 PSI 21 SAFETY Safety Decals and Locations Track Warning Warming Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death No Passenger Warning Warming This vehicle is designed for operator only NO PASSENGER 22 SAFETY Safety Decals and Locations TUE M d i o x 8 Reverse Warning Reverse operation even at low speeds may cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Machine stopped and engine at idle push yellow button on LH control to reverse Flashing light on dash indicates reverse opera tion Push button again to return to forward Elevation setting above 6000 feet push and hold for
33. longer than 5 seconds to set Let go of button at desired setting fast flash for high elevation slower flash for low Setting will remain until changed 23 SAFETY Safety Decals and Locations Operation Warning To avoid serious injury or death read and understand all warnings and the Owner s Manual before operation If the manual is miss ing contact a Polaris dealer for a replacement This vehicle is capable of high speeds Buried objects or un even terrain can cause loss of control Reduce speed and use extreme caution when operating in unfamiliar terrain Excessive speed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes to avoid unexpected obstacles or to stop safely Never consume alcohol or drugs before or while operating this vehicle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age require ments 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 abil
34. snowmobiles contain patented carburetor bowl water sediment traps located at the bottom of each carburetor The trap consisting of a hose with a plug should be drained about every 1000 miles 1600 km and inspected for contamination 4 WARNING When draining the traps fuel spillage will occur Always work in a well ventilated area away from anything that may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the fuel warnings on page 61 Cleaning Procedure 1 Turn the fuel valve off See page 28 2 Place a container or shop towels below the plug to catch drained fuel 3 Slide the clamp 1 away from the drain plug 2 and remove the drain plug from the sediment tube 4 Wipe residue from the plug and reinstall it Reposition and tighten the clamp 5 Repeat the draining procedure for any remaining traps 83 MAINTENANCE General Maintenance 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 6096 antifreeze 40 water mixture See page 108 for the part numbers of Polaris products NOTE Never add tap water to the cooling system Minerals cause deposits and may react adversely with
35. suspension components and grease all pivot points Verify sag dimension see page 42 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Decrease shock compression damping see page 44 Verify sag dimension see page 42 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Move limiter strap on front torque arm to high position see page 43 Verify sag dimension see page 42 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Move limiter strap on front torque arm to low position see page 43 Check for worn skags Check for binding front suspension shafts and steering components grease all pivot points elevate front of machine Verify sag dimension see page 42 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Increase IFS preload premium only see page 40 Move limiter strap on front torque arm to high position see page 43 Check skags and skis for damage Check for binding front suspension shafts and steering components grease all pivot points elevate front of machine Verify sag dimension see page 42 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Decrease IFS preload premium only see page 40 Ensure skis are properly a
36. 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 Engine 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 CAUTION Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recommended 84 MAINTENANCE General Maintenance Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine coolant temperature becomes too hot for safe continued operation of the engine If you must drive your machine 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 NOTE 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 the system should be completely drained every two years and a fresh mixture of antifreeze and distilled water should be added This service must be done when the engine i
37. 240 2871721 2871722 2872347 2574438 2874430 2874443 Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz 2871312 2871322 2871423 2871329 Dielectric Grease Nyogel 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt 108 TROUBLESHOOTING Engine Troubleshooting CAUTION Unless you have experience and training in two cycle engine repair see your dealer if technical problems arise Problem Probable Cause Solution Erratic engine Drive clutch binding SEE YOUR DEALER operating RPM during acceleration Driven clutch SEE YOUR DEALER or load varia malfunction tions clutch too narrow engagement Excessive belt sheave SEE YOUR DEALER Sa Drive belt Wrong belt for Replace the drive belt turns over application Clutch alignment out SEE YOUR DEALER of spec Engine mount broken Inspect and replace SEE YOUR or loose DEALER Machine fails Clutch jammed Check for twisted belt or broken spring to move SEE YOUR DEALER Track jammed Foreign object may be caught or the slide melted to the track clips due to lack of lu brication Track may be iced up or frozen to the ground Chaincase sprocket or Chain is loose or broken or chain tightener chain jammed or is loose SEE YOUR DEALER broken 109 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive
38. G OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEG LIGENCE 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 115 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law How to Obtain Warranty Service If your snowmobile requires warranty service you must take it to a Polaris dealer 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
39. Make sure the battery wires are not stretched tight 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 connectors protective rubber boot Do not spray the back side of the gauge or the wire harness with a pressure washer or other water source CAUTION To prevent damage to the lens do not use alcohol for cleaning Do not allow chemicals or sprays to come into contact with 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 machine should be methodically tested one change at a time under the same conditions trail and snow conditions vehicle speed riding position etc after each adjustment until the best ride is achieved IFS Components 1 Skis 2 Front shocks and springs 3 Rodends 4 A arms IFS Adjustment Opti
40. Reinstall it before starting the snowmobile Drive Belt Removal CAUTION 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 Turn the ignition key off Wait for the engine to come to a complete stop 3 Lock the parking brake 4 Open the hood 5 Remove the left side panel 6 Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves open far enough to remove the belt 93 MAINTENANCE General Maintenance Drive Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack NOTE 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 4 Reinstall the side panel 5 Close and secure the hood 94 MAINTENANCE General Maintenance Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral posi
41. 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 coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper en gine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjust ment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermar ket components resulting in failure unauthorized repairs
42. Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that snowmobiles conform to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter machines we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly Air Pollution Polaris engineers continuously investigate ways to reduce emission levels of two stroke engines We expect our efforts to lead to the reduction of potential air pollution In addition to our technological research we encourage government agencies manufacturers distributors dealers ecologists and other interested parties to work together to develop data on environmental topics INTRODUCTION Vehicle Identification Numbers Record your snowmobile s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number Tunnel VIN X Engine Serial Number on recoil housing Key Nu
43. age at approximately 2000 miles 3200 km To inspect allow the engine and exhaust system to cool completely Open the hood and inspect the muffler and pipes for cracks or damage Check for weak or missing retaining springs or damper support grommets 4 WARNING Hot exhaust system parts can cause serious burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running 81 MAINTENANCE General Maintenance Carburetor The number stamped in the end of the main jet indicates the jet size The jet installed at the time of manufacture is not necessarily correct for your elevation It s your dealer s responsibility to make sure the correct main jet is installed CAUTION Operating the snowmobile with incorrect jetting can result in serious engine damage Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or balanced is important Properly adjusted carburetors can greatly improve engine performance fuel economy engine life and reliability If you notice any of the following conditions the carburetor may need adjustment Hard starting Poor idle Overheated pistons and cylinder walls Plug fouling Poor engine response to various throttle valve openings 82 MAINTENANCE General Maintenance Carburetor Water Sediment Trap Most Polaris
44. an 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Premium Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the container running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel Do not allow the snowmobile to run out of fuel See page 62 If stabilizer is not used drain the carburetors by removing the water trap drain plugs See page 83 NOTE Jet restriction caused by improper storage can cause lean conditions and very poor slow speed driving quality 106 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 See illustration Transporting the Snowmobile Whenever the snowmobile is transported 1 Turn the fuel valve off See page 28 2 Be sure the fuel cap and oil cap are installed correctly 3 Always tie the snowmobile to the transporting unit securely using suitable straps 4 Remove the ignition key to prevent loss 107 POLARIS PRODUCTS Part No Description 2870791 2871098 2871097 2871
45. an the backing plate approximately 1 16 Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thick ness is less than 1 16 1 5mm Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops see page 88 bring the machine to an authorized Polaris dealer for inspection and adjustment 88 MAINTENANCE General Maintenance Brake Fluid 4 WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury 4 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 CAUTION 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 108 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 sufficient the sight glass will be black If the sight glass is any colo
46. ble under this program Snowmobiles used for commercial purposes or for racing are excluded from cover age 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 additional 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 control 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
47. 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 Replace the pressure cap and carefully lower the front end of the machine MAINTENANCE General Maintenance Drive Chain Tension Check drive chain tension weekly and before each long trip To obtain correct chain tension 1 Rotate the driven 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 1 3 Finger tighten the adjuster bolt 2 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 87 MAINTENANCE General Maintenance Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile See page 53 Brake pads must be replaced when the brake pad material becomes thinner than the backing plate approximately 1 16 A kit is available for replacing brake pads See your dealer 4 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 th
48. cal when attempting to service or make adjustments to your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfortable performing these tasks yourself contact an authorized Polaris dealer for service CAUTION Hot components can cause damage to plastic Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection 70 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions You may need to increase frequency based on riding conditions When inspection reveals the need for replacement parts always use genuine Polaris parts available from your Polaris dealer See Frequency Page 500mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season Clutch memor without belt pave serconaton __ _ asasen T foucn sheaves or vr Jj vg Recte __ cem sp etae ed Engine Mounting Piate v v v j Engine Torque Stop 95 1 j v vr Cylinder Head Bolts v j vr j y CylinderBaseNuts r vr j v vr ignition TimingBroc vr v vr ves syet _ p xe oor CoolantLevel _ 8 amp
49. cation Chaincase Oil Oil Change 1 Position the vehicle on a level surface 2 Remove the drain plug 4 and drain the oil into a drain pan Allow the oil to drain completely 3 Install a new sealing washer on the drain plug NOTE The sealing surfaces on the 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 Add 11 oz 325 ml of the recommended oil Do not overfill Reinstall the fill plug making sure it is seated properly DISC de 77 MAINTENANCE General Maintenance Spark Plugs A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization Change the spark plugs every 2000 2500 miles 3200 4000 km CAUTION 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 Use recommended spark plugs with the proper gap Use only resistor type spark plugs Torque spark plugs to 18 22 ft Ibs 24 30 Nm Always carry spare spark plugs 78 MAINTENANCE General Maintenance Spark Plugs Spark plug condition is indicative of engine operation The spark
50. d value If it s not pressed within five seconds the gauge will automatically save the new setting Hour Meter 7 ri fi The hour meter records the total hours of engine operation since manufacture This l LI LI meter cannot be reset MAX RPM F Engine Temperature M ____ A thermometer measures water temperature giving an indication of engine temperature LI l 4 ENG F A w hr 28 34 FEATURES Instrumentation MFD Digital Display Programs History Program The History Program automatically displays electrical system voltage level and fuel level While in the History mode press the SET button to view maximum vehicle speed maximum engine rpm or the current service interval setting The gauge automatically logs the maximum speed and engine rpm even if the History Program is not currently displayed The History Program will display the history of the Maximum Speed Maximum RPM and Service Interval settings Maximum Speed RPM Reset While in either the MAX MPH or the MAX RPM mode press and hold the SET button for three seconds to reset the recorded maximum values for both MPH and RPM Both of these values are reset at the same time Reset the MAX MPH RPM values before each run to obtain accurate readings NOTE Due to electrical noise the MFD may occasionally display MAX MPH RPM values that are not representative of actual values 35 FEATURES Instrumentation MFD Dig
51. dequate 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 CAUTION High speed use on hardpacked surfaces 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 59 OPERATION Track Warm Up 4 WARNING Follow these steps to ensure proper warm up of the engine drive train and track 1 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 throttle during warm up or when the track is free hanging Be sure the rear support 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 indo the snowmobile 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 Start the engine and allow it to warm up t
52. e check all components to be sure of proper operation Read and Understand Your Owner s Manual Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience Throttle Lever The throttle and brake are the primary controls of your snowmobile Always make sure both are functioning properly Squeeze the throttle lever to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately Throttle Safety Switch Test the throttle safety switch system before the machine is operated See page 64 for procedure Seat Latches Ensure that the seat latches are securely in place before every use of the snowmobile 51 PRE RIDE INSPECTIONS Before Starting the Engine 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 snowmobile Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot
53. e to engage clutch gagement 113 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual Contact your Polaris dealer for replacement parts service or warranty Your dealer receives frequent updates on changes 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 1 Serial number 5 Details of trouble experienced 2 Model number Length of time and conditions of operation 3 Dealer name 7 Previous correspondence 4 Date of purchase 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 1 763 417 8650 Canada 1 204 925 7100 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 offi cials the owner must call Polaris Customer Service B Owners must provide their name address telephone num ber and the mod
54. e 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 CAUTION 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 69 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and perform service checks as outlined in this manual Record maintenance and service in the Maintenance Log beginning on page 120 The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles 240 km 500 miles 800 km and 1000 miles 1600 km These inspections should be performed by a qualified service technician For continued optimum performance and component life continue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is criti
55. ealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynamically balanced before installation Any tampering may disrupt this precision balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time especially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the machine into motion but always operate within safety limits Maneuverability While much control and maneuverability is achieved through the steering system and skis maximum control is achieved by the shifting of your body weight Maneuverability will change for lighter operators or machines designed to carry a load 17 SAFETY Operator Safety Inadequate Snow Conditions 4 WARNING Do not drive for prolonged periods on blacktop gravel or ice Doing so could cause irreversible track damage and lead to serious injury 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 machine Driving in too little snow will result in excessive wear and damage to the slide rail track and or engine If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the throttle is opened
56. ealer for service Excessive freeplay in the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the machine 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 machine with the throttle safety switch disconnected Return the machine to an authorized Polaris dealer for service as soon as possible 65 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 64 for more information about the engine stop switch and throttle safety switch SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch ignition circuit AM 66 OPERATION Emergency Starting If the recoil starter system fails an emergency start strap is provided in the tool kit 1 2 3 Open the hood Remove the left side panel Using the belt removal tool follow the directions on the air box to relieve belt tension Starting at one of the tower struts wind the strap counterclockwise around the clutch as shown 4 amp WARNING Serious injury can result from wrapping the start strap around your hand while
57. ecommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine running Track Tension Track adjustment is critical for proper handling Always maintain correct tension and alignment Tension adjustments should be made only after the track is warmed up and limber 1 Turn the machine off 2 Liftthe rear of the machine and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart on page 99 ahead of the center of the rear idler wheel NOTE Measure at the point where the weight is hanging 4 Check for specified slack between the wear surface of the track clip and the plastic rail slide 98 MAINTENANCE Track Maintenance Track Tension If the track needs adjustment Rail Slide 5 Loosen the rear idler shaft bolt D 6 Loosen the locknuts A 7 Tighten or loosen the track adjusting screws B as necessary to provide equal adjustment on both sides of the track C Track 8 Repeat the measurement on the other side of the track NOTE Check more frequently when the machine is new 9 Start the machine 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 100 and adjust as necessary 11 Tighten the locknuts A 12 Tighten the idler shaft bolts D and torque to 35
58. ed be warm and be comfortable when riding Be aware of the weather forecast especially the windchill and dress accordingly See the chart on page 20 4 WARNING Avoid wearing loose clothing or long scarves which can become entangled in moving parts and cause serious injury Always wear an approved helmet and eye protection 11 SAFETY Operator Safety Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Rider Capacity Your Polaris snowmobile is designed for a single rider only Do not carry a passenger Excessive Speed 4 WARNING High speed driving especially at night could result in serious injury or death Always reduce speed when driving at night or in inclement weather Always observe all state and local laws governing snowmobile operation and speed limits Always be alert and pay attention to the trail ahead Multiplying speed MPH by 1 5 will equal the approximate number of feet per second your machine travels If your speed is 40 MPH your machine is traveling about 60 feet per second If you look back for only two seconds your machine will travel about 120 feet If your speed 1s 60 MPH your machine will travel about 180 feet in two seconds Traveling at night requires extra caution Check headlight and ta
59. el 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 114 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 purchase This warranty is transferrable 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 setup of your snowmobile is very important in ensuring trouble free operation Purchasing a snowmobile in
60. ession The seat and suspension of your snow mobile have been designed to provide protection under normal riding conditions Your snowmobile is not intended for this kind of use Be courteous to oncoming traffic by dimming your headlights and reducing your speed When traveling in a group of snowmobiles don t tailgate follow too closely Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris Allow even more distance when driving on slippery sur faces or when driving in darkness or other low visibility conditions Be aware of any snowmobile traffic around your vehicle Drive de fensively to avoid accidents Remove the key from the ignition when you leave the snowmobile unattended 19 SAFETY Operator Safety Windchill Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding WIND CHILL CHART Actual Thermometer Reading F il a TEETE Equivalent Temperature 2 5 5 8 71 1 NL 0 27 21 9 3 16 22 78 35 51 MM ERE 20 8 51212 55 25 2 16 9 3 4 t A 26 pe ee 29 5 55 M 55 7 7 A 21 7 aM 27 20 3 6 1 1 72 29 5 26 19 T2 5 2 9 16 8
61. eter records distance traveled until enough fuel is added to raise the level above 1 4 tank The fuel symbol and the fuel bar will continue to blink until the fuel level is above 1 4 tank The Trip F odometer will automatically reset to zero after refueling Odometer Setting The odometer records the vehicle s total distance traveled since manufacture The odometer cannot be reset 32 FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting 1 While in the CLOCK display press and hold the SET button for five seconds 2 When the hour starts flashing press the SET switch once to advance one hour or press and hold the SET button to advance the hour once every 0 2 seconds 3 Press the MODE button to save the hour and flash the minutes 4 Setthe minutes in the same manner 5 When finished press the MODE button to save the new setting NOTE Ifthe MODE button is not pressed within ten seconds the clock will automatically save the new entry Engine Program The Engine Program automatically displays the engine coolant temperature engine hours electrical system voltage level and fuel level On machines equipped with altimeter sensor and ambient air temperature sensors altitude and ambient air temperature will display as additional screens in the engine program Press the SET button to display the ambient air temperature and altitude screens if equipped Air Temperature
62. foam filter periodically to remove any accumulation of snow CAUTION Operating the snowmobile with the intake filters removed may cause carburetor icing The result will be poor fuel economy or carburetor malfunction Always reinstall the intake filters before operating the snowmobile Fuel Pump fuel pump service must be performed by an authorized Polaris dealer Do not attempt to service the fuel pump Fuel Filter Fuel Lines See your Polaris dealer for replacement of the in tank fuel filter every 1000 miles or annually Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal deterioration from weather and fuel compounds may occur Replace worn or damaged fuel lines promptly CAUTION 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 80 MAINTENANCE General Maintenance Oil Filter Oil Lines Inspect oil line condition at 1000 miles 1600 km The oil filter should be changed annually or every 1000 miles 1600 km The oil filter is A located on the left side of the bulkhead behind the drive clutch Have your dealer perform the filter change and bleeding operation NOTE The direction of the arrows indicates the direction of flow through the filter Exhaust System Check the exhaust system for wear or dam
63. fore operating the snowmobile 54 PRE RIDE INSPECTIONS Before Starting the Engine Track 4 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 lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty Deep Lug Tracks if equipped The 2 4 powder track is designed specifically for deep snow applications 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 CAUTION High speed use on hardpacked surfaces 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 55 PRE RIDE INSPECTIONS Start the Engine and Check Engine Stop S
64. ge will result because of lack of clearance between upper carrier wheels and track Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tunnel Track studding will enhance braking control on hard packed snow or ice but extreme caution is still required on such surfaces Steering ability may be reduced on hard packed snow or ice When studded tracks are used increased wear to the brake pads will result from increased braking Extended wear brake pad kits are available See your dealer CAUTION Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage Center of stud must be at least 1 1 8 2 86 cm from the outside edge of the track 48 THE PERFECT FIT Traction Products SwitchBack only Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain Use carbide skags with studded tracks to help maintain proper vehicle steering and control See page 103 If your machine has carbide skags it may be necessary to add track studs to maintain proper vehicle control Maintain a proper balance between the number of studs and the length of carbide on the skags
65. ght The low oil indicator light will alert the operator if the oil level is low Visually check the oil level in the bottle Add oil before further operation of the snowmobile See page 59 for oil recommendations Low Oil Level Maintaining the proper oil level will prevent system aeration and possible loss of pumping action which could result in engine damage This is especially important when the machine is operated in mountainous terrain CAUTION Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refueling Add oil as needed Always maintain a visible level of oil in the tank If oil is not visible continued operation may cause serious engine damage See page 71 for oil recommendations The Polaris oil cap on the oil bottle is vented to allow proper oil flow See your Polaris dealer for recommended replacement parts 63 OPERATION Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly Pull the switch up to the ON position to allow restarting Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position 4 WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury o
66. hen turned fully to the left or right 4 Torque the handlebar adjuster block bolts to 11 13 ft Ibs 15 18 Nm NOTE Torque the front bolts first 5 Reinstall the handlebar cover 46 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 njury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems NOTE Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service 47 THE PERFECT FIT Traction Products SwitchBack only Studs Before equipping your machine with traction products be aware of the laws in your area pertaining to the use of traction products Use only Polaris traction products on your snowmobile Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non Polaris traction products See your dealer about installing studs and or carbides CAUTION Always install wear strips before installing studs Failure to install wear strips may result in cooler or tunnel damage See page 49 Never add shims to the wear strip Track dama
67. igh 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 OPERATION Engine Break In Cil Injection System Always fill the oil tank when refueling See page 63 CAUTION Serious engine 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 108 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 Polaris oils are compatible with each other Slide Rail and Track Cooling CAUTION Ina
68. il and Track Cooling 59 Slide Rail yi cee sce cee rms 104 Snow Conditions 18 Spark 78 79 Spring Preload 42 Start the Engine and Check 56 Starting a Cold Engine 57 Starting a Warm Engine 58 Starting the Engine 57 58 INDEX S Starting Emergency 67 Steering Adjustment 101 Steering Inspection 101 Steering System 52 101 104 Stopping 66 Storage 69 105 107 Storage Compartment 28 St ds cem dein Src ST 48 Survival Preparation 11 Suspension 107 Suspension Adjustments Front IQ 39 40 Suspension Adjustments Rear 41 45 Suspension Maintenance 104 105 Suspension Performance Tips 41 Suspension Troubleshooting 112 Symbols ene et ree 8 T TABLE OF CONTENTS 3 Taillight Brakelight Replacement 91 Tether Switch 56 THE PERFECT FIT 39 49 Throttle Cable 75 Throttle 65 Throttle Safety Switch 64 96 Torque Stop 95 Torsion Spring Tension 43 olen Bee Reha Paes 69 iot EI 22 107 Track 100 Track 59 Track Inspection
69. illight to ensure proper operation and don t over drive your headlight beam Always be able to bring your machine to a stop in the distance illuminated by the headlight 12 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles posts or other obstacles Be especially alert if you re snowmobiling after dark Always be on the alert for wire fences Single strands are especially dangerous since there may be a great distance between posts Guy wires on utility poles are also difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your machine 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 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 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 13 SAFETY Operator Safety Avalanches Snowmobilers should always be properly
70. ital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders When the logged hours reaches the designated service interval set by the user the gauge provides a reminder that service is due SErVCE will flash in the odometer area and ENG will flash in the icon area for five seconds each time the vehicle is started until the service reminder is reset To reset the reminder at the existing interval 1 Enter the service interval screen 2 Press and hold the SET button for ten seconds continuing to hold even after the display begins to flash 3 When the display stops flashing release the button The service interval has been reset To reset the reminder at a new interval 1 Enter the service interval screen 2 Press and hold the SET button for five seconds until the hours begin to flash 3 Immediately release the button 4 Press the button again up to five times to advance the reminder in 50 hour increments NOTE The maximum interval is 250 hours To disable the service interval reminder press the SET button once after reaching 250 hours on the display The gauge will display OFF 36 FEATURES Instrumentation MFD Battery Replacement If the clock function of the MFD isn t working properly replace the battery Replacement batteries are available from your dealer 1 2 Remove the plenum from the underside of the hood
71. ity are greatly reduced Reduce speed and allow extra space to turn or stop To maintain vehicle control on ice or hard packed surfaces you should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for long periods Do not leave brake engaged for more than five minutes Before starting engine check throttle brake and steering for proper opera tion Make sure hood is latched Be seated and in position to control the ve hicle Oil injection system Use unmixed fuel only Check oil level when refueling 24 gt Hood Headlight Windshield Handlebar Side Shield Seat Storage Compartment Taillights 10 11 12 13 14 15 FEATURES Rear Bumper Snow Flap Suspension Track Nosepan Front Bumper Ski CAONDARWN Fuel Filler Cap Rider Select Ignition Switch Handlebar hook Brake Lever Mountain Bar MFD Multi Function Display Engine Stop Switch Choke Throttle Control Recoil Starter Handle Hood Hold Down Straps Headlight Dimmer Switch Parking Brake Handlebar Grip Warmer Switch Thumbwarmer Switch Electronic Reverse Button MFD Control 14 15 16 17 25 FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system allows you to
72. iveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel This should take approximately two pumps Do not use more than four pumps 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 shown Choke and Cable Lubricate the choke slide and cables lightly with oil or grease Before turning the engine off operate the choke intermittently to draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen 75 MAINTENANCE Lubrication Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 71 The sight glass 1 is located on the lower rear of the chaincase Maintain the oil level at or slightly below the center of the sight glass 2 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 108 for the part numbers of Polaris products Oil Check 1 Position the machine on a level surface 2 View the oil level at the sight glass 3 Remove the fill plug 3 and add the recommended oil as needed Do not overfill 4 Reinstall the fill plug making sure it is seated properly 76 MAINTENANCE Lubri
73. ligned see page 102 Check for binding front suspension shafts and steering components grease all pivot points elevate front of machine Ensure skags are straight on skis TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear Burn Diagnosis Causes Solutions Driving at low RPM Drive at higher RPMs Gear the machine down Check belt deflection Insufficient warm up Warm the engine at least five minutes Take the drive belt off the 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 e Lower the gear ratio Reduce RPM Avoid riding in and slow speed 8000 high ambient temperatures Check for snow ingestion RPM 10 MPH Ice and snow build up Warm the engine at least five minutes Take the drive belt between track and off the machine in extremely cold weather and warm it tunnel up Break machine loose from the snow Poor engine Check for fouled plugs or water ice or dirt in the gas performance tank or fuel line Loading machines onto Skis may gouge into trailers and prevent the drivetrain trailers 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 en Use fast aggressive throttl
74. mber SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury 4 WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death 4 amp CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 70 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals 4 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
75. mmends the use of 91 octane or higher fuel Although 87 octane fuel is usable some engine performance will be lost and fuel economy will decrease Do not use fuel lower than 87 octane CAUTION 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 Level The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1 8th tank There will be approximately one gallon of fuel remaining Refuel as soon as possible Do not allow the snowmobile to run out of 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 engine 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 108 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deicers or water absorbing additives should not be used 62 OPERATION Cil Low Oil Indicator Li
76. nd to prolong the useful life of many components See page 108 for the part numbers of Polaris products 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 machine 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 and cables at the intervals outlined in the maintenance charts beginning on page 71 105 MAINTENANCE Extended Storage 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 Engine Protection Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on precision engine parts during storage Whenever the machine is stored for a period of more th
77. nded 7 After bleeding is complete refill the reservoir to the proper level See page 89 8 Reinstall the gasket and cover 90 MAINTENANCE General Maintenance Removing Halogen Bulbs NOTE Do not 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 fingers do touch the bulb clean it with an alcohol moistened towel Remove the plenum covering from the headlight assembly 5 Lift the rubber boot to expose the bulb Ne Push down on the spring 1 3 to release it from the housing 1 With the wire harness 2 attached to the bulb 3 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 2 3 4 5 6 Hold the bulb by its metal base and install it into the wire harness Insert the bulb into the housing Connect the spring to the housing Carefully flip the spring back into the housing placing it around the wire harness Reinstall the plenum covering on the headlight assembly Verify headlight aim Replacing Taillight Bulbs 1 2 3 Remove the screws securing the taillight lens Push the bulb in and twist counterclockwise and replace the bulb Replace the taillight lens 91 MAINTENANCE General Maintenance Clutch System Periodically inspect clutch sheaves for damage wear or belt residue To maintain optimum
78. needed until the engine starts 4 CAUTION Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Damage may result To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running 7 After the engine starts flip the choke toggle to the OFF position If the engine slows or wants to stop use intermittent choking to the HALF ON position 57 OPERATION Starting the Engine Starting a Warm Engine 1 Turn the key to the ON position 2 Pullthe engine stop switch up to the RUN position 3 Grasp the recoil rope handle and pull slowly until the recoil engages then pull abruptly NOTE Ifthe engine does not start on the first pull slightly depress the throttle with your left hand no more than 1 4 open and pull the rope with your right hand When the engine starts immediately release the throttle 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 injection system will assure proper engine break in 58 CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or h
79. ngine stops running the snowmobile will be in forward gear when it s restarted Disengaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Push the yellow reverse button for one second and release The engine will slow and and begin to rotate forward The light on the instrument panel will shut off 3 Apply the throttle slowly to make sure the machine is in forward 68 Daily Storage At the end of each ride park the snowmobile on a level surface and support it at the rear with an appropriate track stand The track should be suspended approximately 4 10 cm off the ground Remove the key and cover the machine Towing 4 amp WARNING OPERATION Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in the towed object Braking distances increase when towing loads Slow down to maintain control of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach th
80. of steering control resulting in serious injury or death Do not attempt to change the ski alignment or camber adjustment See your Polaris dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement between the skis at point X should be 1 8 to 1 4 greater than the measurement at point Y NOTE Ifthe skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may also be affected 102 MAINTENANCE Steering System Ski Skags 4 amp WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommended skags If you install longer or more aggressive carbide skags than the original equipment it may also be necessary to add track studs to maintain proper vehicle control while turning on hard packed Snow or ice Check skags before each use of the snowmobile to ensure positive steering characteristics Skags must be replaced when worn to half their original diameter NOTE Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement 1 Raise and support the front of the machine so the skis are approximately 6 15 2 cm from the ground 2
81. on Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions However all suspension 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 bottom out harshly on a snow cross course Make adjustments to one area at a time so you can evaluate the change For further assistance 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 a worn slide It can also improve top speed Polaris offers track kits for improved flotation in deep snow See your dealer for assistance NOTE 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 Suspension Maintenance beginning on page 104 41 THE PERFECT FIT Rear Suspension Adjustments Rear Suspension Initial Spring Preload Setting Sag Method To set
82. ons Front shock spring preload Optional springs Optional shock valving if equipped with RydeFX shocks 39 THE PERFECT FIT IQ Front Suspension Adjustments Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions Please see your Polaris dealer for assistance before attempting to adjust preload Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the rear suspension Decreasing the spring preload too much may allow the upper spring retainer to fall off Shock Valving RydeFX shocks can be revalved if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness 4 WARNING Changing shock valving on RydeFX shocks requires special tools and a sound knowledge of mechanical theory tool use and shop procedures to perform the work safely and correctly Shocks contain high pressure nitrogen gas Use extreme caution when handling high pressure service equipment We recommend that this work be performed by a Polaris dealer Front Springs 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 40 THE PERFECT FIT Rear Suspension Adjustments Rider weight riding style trail conditions and vehicle speed all affect suspension acti
83. performance clean with non oil based cleaners such as isopropyl alcohol 4 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 machine 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 CAUTION 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 and Offset Clutch alignment offset is important for maintaining optimum performance See your dealer for service and adjustments A special tool is required to check for proper alignment Clutch Center Distance See your Owner s Manual Supplement for recommended center distance for your machine If adjustment is necessary see your dealer 92 MAINTENANCE General Maintenance Drive Belt Condition 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 See Drive Belt Troubleshooting on page 113 For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature
84. 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 4 WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE Thetip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil or use of non recommended injection oil Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation 4 Torque to 18 22 ft Ibs 24 30 Nm 5 Reinstall the spark plug cap 79 MAINTENANCE General 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
85. press and hold the MODE button for three seconds When the button is released the new setting becomes active and screen colors change See table below Option Analog Digital Analog Digital Display Display Screen Screen 1 Speed Blue mph Blue Backlight 2 Speed Red X100rpm Red Backlight 31 FEATURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs Performance Engine and History Each program will remain in the display until another is selected NOTE The analog will always display either MPH or engine RPM whichever setting is selected regardless of the display program being viewed Performance Program The Performance Program automatically displays either speed or tachometer whichever is opposite the analog display See page 31 It also displays electrical system voltage and fuel levels While in the Performance mode press the SET button to cycle through the odometer Trip 1 Trip 2 Trip F and Clock settings MILES p nm n E Trip Settings Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled 1 To reset a trip odometer to zero enter the Trip 1 or Trip 2 display 2 Press and hold the SET button for two seconds Trip F automatically displays if the fuel level is low The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1 8th tank The Trip F odom
86. r death in the event of an accident If the throttle safety switch does not shut off the engine during a throttle system malfunction immediately push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer Test the throttle safety switch system daily before operation 1 Siton the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration X 4 Apply a slight amount of throttle A properly functioning switch must shut down the engine 64 OPERATION Throttle Lever 4 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 switch 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 If the engine doesn t start take the snowmobile to an authorized Polaris d
87. r other than black add brake fluid 89 MAINTENANCE General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action Bleed the system before operating the snowmobile 4 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 possible 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 4 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 recomme
88. rage 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 114 119 MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile 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 120 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 121 INDEX A Accessories lees 47 Adjustable Headlights 28 Avalanches 14 B B anngs reet 106 Before Starting the Engine 51 55 Belt Troubleshooting 113 Bleeding the Cooling System 86 Bleeding the Hydraulic Brake System 90 Brake Components 88 Brake Fluid 89 Brake Lever Travel 53 Brake Park 54 Bulb Replacement 91 C Carbide 49 Carburetor sic ee be pne 82 Carburetor Adjustments 82 Carburetor Water Sediment Trap 83 Cargo Rack 28 Chaincase Oil 76 77 Choke and Cable 75
89. res 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 2006 600 RMK Switchback Owner s Manual P N 9920058 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 seta eee e nmn pui IM sete 8 This section describes safe vehicle operation and identifies warning decals and their locations aU D PEE 25 This section identifies the locations of your snowmobile s controls and features The Perfect viii sea sna gw a uh xau 39 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 50 This section explains procedures that must be performed before riding 57 This section explains proper engine break in operation of features and general operating procedures Maintenance 70 This section defines your role and your dealer s role in your snowmobile s regular maintenance Polaris Products 108 Troubleshooting
90. s which could result in serious injury or death Always have the brakes serviced at the first sign of sponginess 53 PRE RIDE INSPECTIONS Before Starting the Engine Park Brake Lever Lock Use the park brake lever lock only when you want the machine to remain stationary for example when parked on an incline for a period of five minutes or less 1 Brake Lever 3 2 Park Brake Lever Lock 3 Master Cylinder Reservoir Cover 4 Fluid Level Indicator Lock Engagement To engage the lock squeeze the brake lever tightly and push forward on the lock Hold the lock forward while releasing the brake lever af NOTE Ifthe brake lever is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break The park brake light on the gauge will light up if the park brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the park brake light does not come on when the park 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 unlock position 4 WARNING If the park 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 be
91. s cold Ask your Polaris dealer to check the coolant when he performs the fall tune up on your snowmobile 85 MAINTENANCE General Maintenance Bleeding the Cooling System 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 4 WARNING 86 Steam and hot liquids will cause serious burns to your skin Never bleed the cooling system or remove the pressure cap when the engine is warm or hot CAUTION If coolant flow becomes restricted or plugged coolant loss air lock or engine damage may result Most cooling systems are equipped with a filter that should be periodically inspected or replaced Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark Elevate the front end of the machine slightly to aid in bleeding of the heat exchangers 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 Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air Stop the engine and check the coolant bottle level Fill as required Feel the heat exchangers under the running boards If the system is
92. securing the rope inside the handle is secure If excessive wear is found see your Polaris dealer for replacement Steering System 4 WARNING Ice and snow build up may interfere with the steering of your machine 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 NOTE f your snowmobile is equipped with RIDER SELECT perform this check in both the full up and full down steering positions 52 PRE RIDE INSPECTIONS Before Starting the Engine Brakes Always check the 1 2 following items for proper operation before starting 1 3 S the engine Brake Lever Travel Squeeze the brake lever It should move no closer to the handgrip than 1 2 1 3 cm A smaller distance indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding information on page 90 n Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 89 Check for the presence of air in the fluid system See page 90 for more information or see your dealer for service 4 WARNING Continued use of spongy brakes may cause a complete loss of brake
93. the crate or without proper dealer setup will void your warranty coverage Warranty Coverage and Exclusions Limitations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for purposes other than for which it was manufactured The warranty does not cover any damages that oc cur during trailer transit or as a result of unauthorized service or parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or punc turing of upholstery material corrosion or defects in parts components or the snowmo bile 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 ARISIN
94. tion Place a straight edge on the belt A and apply downward pressure while measuring at point B This measurement should be 1 1 4 3 2 cm Drive Belt Adjustment TEAM Clutch 1 Loosen the 7 16 jam nut on the belt width adjuster 2 Using a 1 8 Allen wrench adjust the threaded set screw as needed NOTE Turn the set screw in clockwise to increase the distance between the sheaves and out counterclockwise to decrease the distance 3 Tighten the jam nut Torque Stop Periodically check torque stop clearance With clutches in proper alignment the clearance should be a minimum of 010 to a maximum of 030 from the engine case Adjust if necessary Lock the jam nut 2 010 030 D 25 75mm o 9 9 9 MAINTENANCE General Maintenance Tool Kit A tool kit is included with each machine for emergency and routine maintenance Always keep the tool kit with the snowmobile 1 Emergency Start Strap 2 L Wrench 3 Spark Plug Wrench Screwdriver 4 Scissor Stop Wrench 5 Combination Wrench 6 Open End Wrench Fall Tune Up For maximum performance arrange for a fall service tune up with your Polaris dealer 96 MAINTENANCE Track Maintenance Track Inspection 4 WARNING Broken track rods are a serious safety hazard They can cause a rotating track to come off the machine which could cause serious injury or death
95. ty 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 customs 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 cove
96. 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 NOTE Therear bumper may need to be lifted upward slightly to fully extend the suspension Next have the rider drop down hard on the seat and bounce up and down several times collapsing the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y from X Sag X Y Adjust sag by rotating the torsion spring preload cams located on the rear torque arm See illustration The ideal amount of sag for the IO rear suspension is five inches X Y 5 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 42 THE PERFECT FIT Rear Suspension Adjustments Rear Torsion Spring Tension To adjust rear torsion spring tension rotate the three position cam using the engine spark plug tool Different rate torsion springs are available if a firmer ride is desired
97. using the emergency starting procedure DO NOT wrap the start strap around your hand Keep all bystanders and loose clothing away from the snowmobile when using the emergency starting procedure Pull the strap abruptly so the strap comes free of the clutch while starting the engine Repeat until the engine starts Reinstall the side panel Close and secure the hood 67 OPERATION Electronic Reverse PERC Electronic reverse will activate only if the engine RPM is below 4000 4 WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle Look behind the vehicle before and while backing Avoid sharp turns Apply throttle slowly Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your vehicle is clear 3 Push the yellow reverse button on the left hand control for one second then release The engine will automatically reduce RPM and start a reverse rotation A flashing reverse light on the instrument panel will indicate that the machine is in reverse 4 Apply the throttle slowly to make sure the machine is in reverse NOTE The maximum engine RPM will be 6000 when in reverse NOTE Ifthe e
98. val Table See Page 50 500mi 1000mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season T34 SwmeAgmet Ex a d Mounting Bolts Steering Fasteners 7 _ Fasteners Drive Shaft Bearings 107 JackshaftBearings 106 Ska Wear Bars SKSaddeSpdeBos MEM peres Idler Bolt Nut Bolt Jam Nut ERU Suspension Pivot Shafts CamberAignment CES M E ether Swich ana svap se rack Aignment 3 Task Terson 9 1 1 3 1 1 74 1 _ 7 Chaincase Oi 1 8 Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 73 MAINTENANCE Lubrication Front Suspension The front suspension and steering components do not require lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium Season Grease at 500 miles 800 km initially every 1000 miles 1600 km after that and before off season storage each year Lack of lubrication will adversely affect your ride and the life of the suspension For more information about suspension lubrication and adjustments see your Polaris dealer 74 MAINTENANCE Lubrication Dr
99. witch Check the auxiliary shut off switch for proper operation Push the switch down to stop the engine Pull it up to allow restarting Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF Tether Switch If 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 advantage Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the machine 56 OPERATION Starting the Engine 4 WARNING Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start your snowmobile without checking all components to be sure of proper operation See Check Before Starting the Engine beginning on page 51 Starting a Cold Engine Do not depress the throttle until the engine starts CHOKE TOGGLE POSITIONS 1 Turn the fuel valve on OFF See page 28 2 Turn the key to the ON position 3 Pull the engine stop switch up to the RUN HALF ON position 4 Flip the choke toggle to FULL ON 5 Grasp the recoil rope handle and pull slowly until the recoil engages FULL ON then pull abruptly 6 Repeat as
100. wo to three minutes Depress the throttle abruptly and allow the track to rotate several revolutions NOTE t will take longer to warm up the track sufficiently during 60 colder outdoor temperatures Release the throttle apply the brakes shut off the engine and lower the machine to the ground Grasp the skis by their front loops and move them from side to side to loosen snow and ice OPERATION Fuel 4 WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel outdoors or in a well ventilated area Always turn off the engine before refueling Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of conscious ness or death in a short time Turn the fuel valve off whenever the snowmobile is stored or parked 4 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 61 OPERATION Fuel For peak performance Polaris reco
101. y interfere with the handlebar Such accessories could limit your ability to steer the vehicle and or may contact the brake lever This could lead to loss of control resulting in serious injury or death Always be sure that accessories do not contact the handlebar or brake lever at any steering position and at any RIDER SELECT position Adjustable Headlights Adjust the headlight beam by moving the adjuster to the left or right 27 FEATURES Fuel Valve The fuel valve is located under the 1 hood Turn the fuel valve off whenever the snowmobile is stored or parked 5 Turn the valve clockwise to turn off the fuel supply 2 Turn the valve counter clockwise to turn on the fuel supply Seat Storage Compartment Lift the seat lever and lift the seat to access the under seat storage area Radiator Compartment Access Panel The access panel is provided for cleaning debris from the radiator Cargo Rack The maximum weight capacity for the cargo rack is 15 Ibs 7 kg Always secure cargo before operating Do not exceed the rack weight limit Do not allow a passenger to sit on the seat back or the cargo rack 28 FEATURES Detonation Elimination Technology D E T The DET system prevents damage to the engine from detonation while developing the maximum power of the engine safely A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing

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