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Polaris 600 Dragon SP Offroad Vehicle User Manual

1. 62 111 114 Stopping Emergency 74 Storage Daily 77 Storage Extended 115 117 STS eset oh Ac ae ea ae Ra 56 Survival Preparation 12 Suspension Adjustments Rear 46 53 Suspension Coupling IQ 51 Suspension Inspection Pre Ride 114 Suspension Maintenance 114 Suspension Performance Tips 45 Suspension Rear Lubrication 83 138 T Taillight Brakelight Replacement 100 Throttle Cable 2 84 Throttle Lever 59 73 Throttle Safety Switch 59 72 Torque Stop 0005 105 Torsion Spring Preload IQ 48 OWING 3 is cine ssid 5 66 t o GOENA 77 Track 02 eta N EE nee 62 Track Alignment 110 Track Care for Storage 117 Track Inspection 106 Track Lubrication 107 Track Maintenance 106 110 Track Safety 005 10 Track Tension 45 108 109 Track Warm Up 68 Track Warning 24 Traction Products 56 57 Transporting the Snowmobile 117 Troubleshooting Drive Belt 123 Troubleshooting Engine 119 121 Troubleshooting Suspension 122 TuneUp osc b ad asawdaadian ne 106 V Vehicle Identification Numbers 5 W Wear Stips 0006 57 Weight Transfer 53 Windchill 0 0000 22
2. Stay Clear of Engine Never attempt adjustments with the engine running Turn off the igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation A WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience and the features available on some snowmobiles but under many conditions the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle brake and steering control A 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 Riding Apparel Be prepared be warm and be com fortable when riding Be aware of Y estaris the weather forecast especially the windchill and dress accordingly See the chart on page 22 A WARNING Avoid wearing loose clothing or long scarves which can become entangled in moving parts and cause serious injury Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds
3. 41 THE PERFECT FIT Front Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski to ground pressure Decreasing spring preload will decrease ski to ground pres sure When adjusting be sure the springs on both the left and right sides of the l gt machine are at the same adjustment To change front shock spring preload grasp the spring and rotate it Low Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension Never exceed one inch of pre load beyond the factory settings and ensure that both sides are adjusted the same When decreasing preload make High sure at least two turns of preload are hold Preload Preload ing the spring between the retainer on the top of the shock and the threaded spring preload adjuster nut on the shock body Failure to do so could cause the retainer to fall off when the suspension is fully extended TIP Not all models have shocks with thread adjustable spring preload See your dealer for more information NOTICE On some models equipped with a plastic adjuster nut the nut will break if it is unscrewed from the threaded body Do not force the nut if resistance suddenly increases while you re turning it 42 THE PERFECT FIT Front Suspension Adjustments Shock Compression Damping SP models Turn the
4. 70 G Gauge Cleaning 40 H Handlebar Adjustments 54 Handlebar Angle 54 Handlebar Position 54 Headlight Adjustment 29 Headlight Bulb Installation 99 Headlight Bulb Removal 99 High Temperature Light 92 Hood Latches 63 Hot Surface Warning 24 l Ice and Snow Build up 16 TES eke bee be a a E r e 41 IFS Adjustment Options 41 IFS Components 41 Inadequate Snow Conditions 20 Instrumentation 30 40 Intake Filters 90 Intake Silencer 19 L Lights iriran tintat teens 99 100 Limiter Strap Position SwitchBack 49 Low Oil Indicator Light 71 Lubrication 83 86 M Maintenance Interval Table 80 82 Maintenance Program 79 Maneuverability 19 MFD Battery Replacement 39 40 MED Components 30 MFD Digital Display Programs 32 38 MFD Settings 31 N NOISE shit sien a ee aes ARS 6 0 Qil Filtet groenen ee 89 Oil Indicator Light 71 Oil Injection System 67 Ou Levels onase ea ask eet eee 71 OLES is hae Set bs ANAA eta 89 Oil Recommendations 67 Operating in Deep Snow 20 Operation Warning 25 26 Operator Safety 8 22 P Parking Brake Lever Lock 61 Pa
5. Administration 1 Polaris snowmobile owner reports theft A In addition to notifying the proper law enforcement officials the owner must call Polaris Customer Service B Owners must provide their name address telephone num ber and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notifying the proper owner when a unit is recovered 125 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 transferable to another consumer during the war ranty period through a Polaris dealer Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact y
6. Tether Switch Strap if equipped 64 Track Alignment Condition 62 110 Rail Slide Condition 114 Chaincase Oil Level 85 Injection Oil Level 71 58 PRE RIDE INSPECTIONS Before Starting the Engine Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start the engine without checking all vehicle components to be sure of proper operation A WARNING Operating the vehicle with worn damaged or malfunctioning components could result in serious injury or death Never start the engine without check ing all vehicle components to be sure of proper operation Read and Understand Your Owner s Manual Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience X Throttle Lever The throttle and brake are the primary controls of your snowmobile Always make sure both are functioning properly Squeeze the throttle lever to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not func tion smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately X Throttle Safety Switch Test the throttle safety switch system before the machine is operated See page 72 59 PRE RIDE INSPECTIONS Before Starting the Engine Brakes Alwa
7. This limited warranty also does not cover any engine that has been structurally altered or when the snowmobile has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris can deny an emissions warranty claim if any specified critical emissions related maintenance is not performed Performance of other scheduled maintenance is strongly recommended but is not necessary to keep the emissions related warranty valid Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your snowmobile Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary for your snowmobile Polaris also recommends that you use only Pure Polaris parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law 132 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES
8. harness from the point where the harness connects to the MFD Cut the plastic cable tie from the out side of the compartment Carefully cut the bottom of the com partment opposite the wires to separate the heat sealed seams Squeeze the corners of the compartment inward so the battery is visible Note the orientation of the battery before removing it An incorrectly installed battery will not maintain the clock Using needle nose pliers grasp the battery and rotate it so the lead ing edge of the battery is raised slightly away from the battery holder Pull the battery out gently 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 remov ing the battery Pulling on the wires will separate them from the battery holder 39 FEATURES Instrumentation MFD Battery Replacement models with clocks 6 Tk 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 Make sure the battery wires are not stretched tight Gauge Cleaning 1 2
9. out of direct sun light 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 as outlined in the Periodic Mainte nance Table beginning on page 80 115 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 preven tion of rust and corrosion on precision engine parts during storage Whenever the machine is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container 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 116 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors Be sure wiring harness is pro
10. 29 33 37 42 96 3 8 12 16 21 25 29 34 38 42 Frostbite in gt gt 30 min 10 min WINDCHILL CHART C Wind Actual Thermometer Reading C Spoed 5 2 1 4 7 1 10 13 16 19 22 25 28 31 34 37 40 43 46 KPH Equivalent Temperature C Cam 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 3 o 4 7 11 14 18 22 25 29 32 36 39 43 46 50 53 57 16 2 2 6 10 13 17 21 24 28 32 36 39 43 47 50 54 58 62 1 0 22 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protec tion Read and follow the instructions of the decals and other warnings on the snowmobile carefully If any of the decals depicted in this manual 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 WARNING Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with plenum
11. Skags A WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommended skags If you install longer or more aggressive carbide skags than the original equipment it may also be necessary to add track studs to maintain proper vehicle control while turning on hard packed snow or ice Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter TIP Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement Some models are equipped with single skags Some models are equipped with dual skags 1 Raise and support the front of the machine so the skis are approximately 6 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse the steps to install a skag Skag 113 MAINTENANCE Steering System YX Rail Slide Wear Measure slide thickness at several points along the rail 7 16 Have your dealer replace the if 1 cm slide when it s worn down to vy the top of the wear limit indicator groove Do not operate the snowmobile if slide thickness measures less than 7 16 1 1 cm Suspension Maintenance i Pre Ride Suspension Inspe
12. TECHNICIAN SERVICE PERFORMED COMMENTS KM 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km 133 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS KM 134 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 135 INDEX A Accessories 00 004 55 Adjustable Headlights 29 Air Pollution 6 Avalanches 000 15 B BearingS 00a ee 116 Brake Components 96 Brake Fluid 97 Brake Inspection 96 Brake Lever Travel 60 96 Brake System Bleeding 98 Brakelight Replacement 100 Brakes 4 ui Taeg 60 96 98 Cc Carbide Skags 57 Cargo Area 0 0000 29 Chaincase Oil 85 86 Choke moeien iape n EE 85 Cleaning and Preservation 115 Clutch Alignment Offset 101 Clutch and Drive System 116 Clutch Center Distance 101 Clutch Cover Warning 23 Clutch Safety 0 19 Clutch System 101 105 Cold Weather Drive Away 19 Compression Damping Rear Shock Premium Shock 50 Front Track Shock SP Model 50 Controls and Linkage 115 Coolant ops fst
13. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution Wipe dry with clean soft cloth Clean the back side of the gauge using a clean cloth and a mild soap and water solution Do not remove the electrical connectors or pro tective rubber boot Do not spray the back side of the gauge or the wire harness with a pressure washer or other water source NOTICE To prevent damage to the lens do not use alcohol for cleaning Do not 40 allow chemicals or sprays to come into contact with the lens Immedi ately clean off any gasoline that splashes on the gauge during refuel ing THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension IFS Break in the suspension for about 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 Rod ends 4 A arms IFS Adjustment Options Front shock spring preload e Optional springs e Optional shock valving e Compression damping SP models
14. adequate engine lubrication can result in serious engine damage Always check the oil level when refu eling 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 67 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 71 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 y 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 A WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a carburetor throttle system malfunction immediately push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer Test the throttle safety switch system daily before operation 1 Sit on the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pres su
15. adjuster to make adjustments to the compression damping When adjusting we recommend that you turn the adjuster only one click then test ride Always adjust both shocks equally S The standard setting is 4 clicks from Stiffer 0 the softest position SS Turn the adjuster to the left for a stiffer ride e Turn the adjuster to the right for a softer ride Shock Valving Some shocks can be revalved if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness Please see your Polaris dealer A WARNING Changing shock valving 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 cau tion when handling high pressure service equipment We recommend that this work be performed by a Polaris dealer 43 THE PERFECT FIT Rear Suspension Adjustments Rider weight riding style trail conditions and vehicle speed all affect suspension action Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions However all sus pension designs and adjustments involve a compromise or trade off For example a suspension set up for snowcross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bot tom out harshly on a snowcross cou
16. ahead Multiplying speed MPH by 1 5 will equal the approximate number of feet per sec ond 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 sec onds your machine will travel about 120 feet If your speed is 60 MPH your machine will travel about 180 feet in two seconds Traveling at night requires extra caution Check headlight and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your machine to a stop in the distance illumi nated by the headlight 13 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles posts or other obstacles Be especially alert if you re snowmobiling after dark Always be on the alert for wire fences Single strands are especially dangerous since there may be a great distance between posts Guy wires on utility poles are also difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your machine will drown out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or high ways Steep embankments may also hide your view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Avoid travelling on frozen bodies of wate
17. are a aaa ar 91 Coolant Level 0 91 Cooling System 91 93 Cooling System Bleeding 93 Cooling System Flushing 92 Customer Service 124 136 D DET aari aana heated 29 Detonation Elimination Technology 29 Digital Display 30 Disabled Operators 12 Drive Belt 005 19 Drive Belt Adjustment 103 Drive Belt Condition 102 Drive Belt Deflection 103 Drive Belt Installation 105 Drive Belt Removal 104 Drive Chain Tension 95 Driver Awareness 14 Driveshaft Bearing 84 Driving Downhill 17 Driving in Hilly Terrain 18 Driving on Slippery Surfaces 16 Driving Responsibly 21 E Electrical Connections 117 Engine Break In 66 67 Engine Protection 116 Engine Restarting 65 Engine Safety 10 Engine Starting 65 Engine Stop Switch 72 Environment 00 6 Exhaust System 94 F Front Rear Scissor Stop 51 Front Suspension Adjustments 41 43 Front To Rear Coupling 51 ERSS o oea he aA eS 51 Bue eiss sutsua doh keds end 69 70 Buel Filter rosenn orket EKIA 90 Puel Cin s erseeni paiaina 90 Fuel Pump 05 90 Fuel System Deicers
18. belt guard removed Never run engine with drive belt removed Never service clutches yourself see your dealer Pressure Cap Warning This warning decal is found under the hood on the pressure cap of appli cable liquid cooled models Do not open hot Test or replace when changing coolant Press down and turn to release cap 13 PSI 23 SAFETY Safety Decals and Locations No Passenger Warning Snowmobiles designed for a single rider only have the NO PASSENGER warning decal on the lower left side of the console WARNING This vehicle is designed for operator only NO PASSENGER One Passenger Warning eras Snowmobiles designed for an operator and one passenger have the ONE PASSEN GER warning decal below the steering post WARNING This vehicle is designed for operator and ONE passenger only One Passenger Warning For more information about operating with a passenger see page 13 Hot Surface Warning The hot surface warning is located near Hot Surface Warning the rear of the tunnel WARNING HOT SURFACE DO NOT TOUCH Burn may result Entire top of tunnel may be hot Install only accessories specifically approved for this model by Polaris Track Warning The track warning decal is at the rear of the tunnel WARNING Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death Track War
19. blockage and reduced cold weather flow rates All Polaris oils are compatible with each other Slide Rail and Track Cooling NOTICE Inadequate cooling and lubrication will lead to overheating of the slide rail and track resulting in premature wear and failure Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating on ice hard packed surfaces or roads 67 OPERATION Track Warm Up A WARNING A loose track or flying debris could cause serious injury or death Stand clear of the front of the machine and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throt tle during warm up or when the track is free hanging Use a stable rear sup port A WARNING Use of traction products such as studs ice growsers etc will increase the possibility of track damage and or failure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up of the engine drive train and track 1 Use an appropriate stand to securely sup port the rear of the snowmobile at the rear bumper The track should be about 4 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the tra
20. broken Chain is loose or broken or chain tightener is loose SEE YOUR DEALER 119 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive sys tem Broken drive clutch components e SEE YOUR DEALER Bearing failure chaincase jackshaft or front drive shaft e SEE YOUR DEALER Drive belt surface flat spots e Inspect and replace as needed Drive chain loose Inspect and adjust or replace Drive chain worn e SEE YOUR DEALER Engine doesn t turn sprocket teeth bro ken Poor low RPM per Worn drive belt e Inspect and replace as needed formance Excessive belt sheave clearance e SEE YOUR DEALER Loose torque stop Sticky clutch e Inspect and adjust e SEE YOUR DEALER Poor fuel quality Seized engine e Use 87 91 octane fuel or higher e SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fuel supply broken parts or improper cooling Hydrostatic lock e Fuel may have entered the crankcase while the vehicle was standing or being transported SEE YOUR DEALER to correct the cause Drain plug s are located on the lower crankcase for emergency draining 120 Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails to start Faulty ignition TROUBLESHOOTING e Install new spark plug s If engine still fails to start check for spark If t
21. engine is running Never start the engine without checking all vehicle components to be sure of proper operation See Before Starting the Engine beginning on page 59 Engine Stop Switch Check the auxiliary shut off switch for proper operation Push the switch down to stop the engine Pull it up to allow restarting Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF 1 Tether Switch if equipped If your machine has a tether switch remove the tether from the switch to make sure the engine stops immediately vy Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating Mirrors if equipped Adjust the mirrors so they can be used to their full advantage Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the machine 64 OPERATION Starting the Engine NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running 1 Turn the key to the ON position 2 Pull the engine stop switch up to the RUN position 3 Ifequipped with electric start turn the key to START to crank the engine Release the key to the ON position when the engine starts 4 Ifnot equipped with electric start grasp the starter handle and pull slo
22. established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean 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 Survival Preparation For your safety always ride in a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited
23. of the electrical box which is mounted to the clutch cover For improved drive away during extremely cold tem peratures remove the belt and warm it to room tem perature Reinstall it before starting the snowmobile 102 Clutch System y Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge 1 on the belt and apply downward pressure while measuring at point 2 This measurement should be 1 1 4 3 2 cm Drive Belt Adjustment MAINTENANCE 1 Install the L wrench into the open threaded hole in the outer sheave of the clutch see page 104 Turn the wrench clockwise slightly to remove pressure from the sheaves Loosen the 7 16 jam nut 3 Usinga 1 8 Allen wrench turn the set screw inward clockwise to increase the distance between the sheaves or outward counter clockwise to decrease the distance 4 Tighten the jam nut Remove the L wrench and store it in the tool kit 103 MAINTENANCE Clutch System Drive Belt Removal NOTICE Do not attempt to remove the drive belt after operating in reverse The 104 snowmobile must be stopped after forward motion to prevent damage to components during belt removal Rotate the driven clutch counter clockwise 1 4 turn by hand to ensure forward engagement before attempting to remove the belt Stop the engine after operat ing in a forward motion Turn the ignition k
24. 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 Clean off all metal shavings from the plug Add 11 oz 325 ml of the recommended oil Do not overfill Reinstall the fill plug making sure it is seated properly GOS ON 86 MAINTENANCE Spark Plugs A new engine can cause temporary spark plug fouling due to the preser vative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization Refer to your Owner s Manual Supplement for the specific spark plug to be used in your machine Change the spark plugs every 2000 2500 miles 3200 4000 km e Use recommended spark plugs with the proper gap e Use only resistor type spark plugs e Torque spark plugs to 18 22 ft lbs 24 30 Nm e Always carry spare spark plugs NOTICE Using non recommended spark plugs can result in serious engine damage A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile See your Owner s Manual Supplement 87 MAINTENANCE Spark Plug Condition Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher s
25. proper vehicle control Maintain a proper balance between the number of studs and the length of carbide on the skags the more studs you use the longer the carbide on the skags should be See your dealer s track studding chart Wear Strips To avoid excessive tunnel wear tunnel wear strips must be installed whenever track studding is used Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction accesso ries NOTICE 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 57 PRE RIDE INSPECTIONS Pre Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile Procedures are outlined on the refer enced pages Look for a checkmark on the referenced pages to locate the pre ride inspection items Item See Page Drive Belt Condition 102 Steering System 62 Recoil Rope 63 Coolant Level 91 Parking Brake Lock Brake Lever Brake System 60 61 96 Auxiliary Shut Off Switch Engine Stop Switch 64 Ignition Switch 64 Taillight Brakelight Headlight 64 Suspension Mounting Bolts 114 Skags Wear Bars 113 Ski Saddle and Spindle Bolts 114 Hood Sitraps Latches 63 Seat Latches if equipped 63 Throttle Lever Safety Switch 72 73 Rear Wheel Idler Bolts 109
26. slide wear occurs due to poor snow conditions addi tional wheel kits are available See your dealer for more information Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty 107 MAINTENANCE Track Maintenance A WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine run ning Track Tension Track adjustment is critical for proper handling Always maintain cor rect tension and alignment TRACK TENSION DATA CHART Suspension Slack Measurement Weight Measurement Location IQ 121 7 8 1 1 8 2 2 2 9 cm 10 Ibs 16 40 cm 7 T 7 4 54 kg ahead of rear Switchback 136 7 8 1 1 8 2 2 2 9 cm idler shaft TIP Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off Lift the rear of the 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 ahead of the center of the rear idler wheel 4 Measure at the point where the weight is hanging 108 MAINTENANCE Track Maintenance Track Tension 5 Check for specified slack between the wear surface of the track clip and the plastic slider Refer
27. the track tension maintenance sec tion beginning on page 108 45 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting Sag Method To set up the rear suspension tor sion spring preload measure the distance between the ground and rear bumper This is measurement X Take the first measurement with no rider and with the rear suspension at full extension The rear bumper may need to be lifted upward slightly to fully extend the rear sus pension Next have the rider drop down hard on the seat and bounce up and down several times collapsing the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact location used for measure ment X This is measurement Y 46 lt x gt lt lt THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting Sag Method To determine sag commonly referred to as ride in subtract measure ment Y from X sag X Y If the measured sag is incorrect adjust the FRA position and or rear torsion spring preload Suspension Recommended Sag Adjustment Sa IQ 121 4 5 inches 10 13 cm Torsion Spring 48 Preload SwitchBack 4 5 inches 10 13 cm Torsion Spring 48 136 Preload TIP This is only an initial setup and final spring preload may vary based on rider preference and riding conditions 47 THE PERFECT FIT Rear Suspension Adjustments Tors
28. to the Track Tension Data Chart on page 108 If the track needs adjustment 6 Loosen the rear idler shaft bolt 7 Loosen the locknuts Adjusting Screw Slack Measurement Lock Nut e 16 40 cm 10 Ibs 4 54 kg 8 Tighten or loosen the track adjusting screws to provide equal adjust ment on both sides of the track 9 Repeat the measurement on the other side of the track TIP Check more frequently when the machine is new 10 Start the machine and slowly rotate the track at least five revolu tions Let the track come to a stop do not apply brakes 11 Check track alignment see page 110 and adjust as necessary 12 Tighten the locknuts 13 Tighten the idler shaft bolts 14 Torque idler shaft bolts to 35 ft lbs 47 5 Nm 109 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 are evenly spaced on each side If the track runs to the left loosen the idler shaft bolts then loosen th
29. transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performance An adjustment dot is located on the RRSS This dot is on the longest end of the scissor stop Rear Rear Scissor Stop RRSS Attributes Moving the RRSS to a higher position will have the following effects on the suspension e Reduced weight transfer Improved chatter bump ride e Improved cornering performance 52 THE PERFECT FIT Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for control ling weight transfer during accel HIGH eration is by adjusting the rear rear LOW LOW scissor stop RRSS The factory setting is the best for most trail MEDIUM riding conditions To decrease weight transfer under acceleration for improved corner gt ing rotate the RRSS to a higher position To increase weight transfer or ski lift during acceleration rotate the RRSS to a lower position TIP Your dealer can help you with ini tial setup and additional setup instructions to help you achieve your optimum ride A scissor stop tool is also available from your dealer 53 THE PERFECT FIT Handlebar Adjustments Handlebar Position 1 Loosen the four bolts on the bottom of the adjuster block If necessary pry the blocks apart with a screwdriver 2 Adjust the handlebar forward or rearward to the desired position 3 Tighten the bolts Loos
30. wildlife and vegetation Snowmobile clubs and other organizations are working together to pro tect our environment Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that snowmobiles conform to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE 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 lev els 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 ke
31. 35 40 45 5 36 31 25 19 13 7 1 5 11 16 22 28 34 40 46 52 57163 10 34 27 21 15 9 3 4 10 16 22 28 35 41 47 53159 66 72 15 32 25 19 13 6 20 30 24 17 11 4 2 9 15 22 29 35 42 48 55 61 3 7 0 25 29 23 16 30 28 22 15 35 28 21 14 40 27 20 13 45 26 19 12 50 26 19 12 55 25 18 11 5 12 19 26 33 39 46 53 7 14 21 27 34 41 48 1 8 15 22 29 36 43 50 16 23 30 37 44 3 10 17 24 31 38 45 3 11 18 25 32 39 46 3 11 19 Frostbite in gt gt 30 min 10 min A A GT N j i N 1 o 24 3 7 11 15 19 22 26 30 34 38 42 45 49 53 57 32 4 8 12 16 20 24 28 32 36 39 43 47 51 55 40 1 5 9 13 17 21 25 29 33 37 41 45 49 53 48 1 5 9 13 18 22 26 30 34 38 42 46 50 56 2 6 10 14 18 22 26 31 35 39 43 47 64 2 6 10 15 19 23 27 31 35 40 44 48 72 2 7 11 15 19 23 28 32 36 40 45 15 88 3 7 12 16 20 24
32. Bleed the system before operating the snowmobile A WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Never operate the vehicle with a spongy feeling brake lever During the bleeding procedure keep the brake handle as level as possi ble The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent 1 Remove the brake master cylinder reservoir cover and gasket 2 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 open ing 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 A WARNING Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock resulting in serious injury or death Always add brake fluid to the fill line as recommended 7 After bleeding is complete refill the reservoir to the proper level See page 97 8 Reinstall the gasket and cover 98 MAINTENANC
33. E Lights 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 fin gers do touch the bulb clean it with an alcohol moistened towel Headlight Bulb Removal l 2 3 Remove the plenum covering from the headlight assembly Lift the rubber boot to expose the bulb A V AS Push down on the spring 1 3 to release it from the housing With the wire harness 2 attached to the bulb 3 with draw the bulb from the hous ing Grasp the bulb by its metal base and carefully separate the bulb from the harness Headlight Bulb Installation l Hold the bulb by its metal base and install it into the wire harness TIP Recommended replacement bulbs include H4 HB2 and 9003 bulbs 2 3 4 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 99 MAINTENANCE Lights Taillight Brakelight Replacement 1 Remove the screws securing the taillight lens Remove the lens 2 Push the bulb inward and turn it counterclockwise to remove it 3 Install a new bulb Push the bulb inward and turn it clockwise to secure it 4 Reinstall the taillight lens 100 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage wear or belt re
34. HE REM EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLI GENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclu sion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 126 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT 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
35. L L l Jackshaft Bearings 116 L L L l Skags Wear Bars 113 l l l l l Ski Saddle Spindle l l l l Bolts Drive Chain Tension 95 l l l l l Hood Latches 63 l l l l l Rear Wheel Idler Bolts 109 l l l l l Idler Bolt Jam Nut 109 l l l l l Rear Suspension Pivot 83 L L L Shafts Steering Post U Joint 83 L L L Camber Alignment l l l Handlebar Centering l Tether Switch and Strap 64 l l l l l Track Alignment 110 l l l l l Track Tension 108 l l l l l Front Limiter Strap l l l l l Rail Slide Condition 114 l Chaincase Oil 85 l l R l Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 82 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 79 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the life of the sus pension For more information about suspension lubrication and adjust ments see your Polaris dealer IQ 121 Switchback 136 Rear Suspension ats ee Y lear i A IQ 121 Shown The Dragon SP rear suspension has no grease points it does not require lubrication 83 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the x sp
36. MODE button to cycle through the three MFD programs Per formance Engine and History Each program will remain in the display until another is selected TIP The analog will always display either MPH or engine RPM whichever set ting 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 level if equipped While in the Performance mode press the SET button to cycle through the odometer Trip 1 Trip 2 Trip F if equipped with electronic fuel gauge and Clock settings 32 Instrumentation MFD Digital Display Programs 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 If the snowmobile is equipped with an electronic fuel gauge Trip F automati cally displays when 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 odometer 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 res
37. Pantone 7427 C 600 800 IQ 10 Shift 136 600 800 Dragon SP 600 800 Switchback 600 800 Dragon Switchback bile Owner s Manual for Maintenance and Safety POLARIS The Way Out Pantone 7427 C For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9921220 Rev 01 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 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris enthusiasts Be sure to visit us online at www polarisindustries com for the latest news new product introduc tions upcoming events career opportunities and more Here at Polaris we proudly produce an exciting line of utility and recre ational products e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the
38. ailure to install wear strips may result in cooler or tunnel damage See page 57 Never add shims to the wear strip Track damage 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 abil ity 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 avail able See your dealer NOTICE 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 The center of the stud must be at least 1 1 8 2 86 cm from the outside edge of the track 56 THE PERFECT FIT Traction Products 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 113 If your machine has carbide skags it may be necessary to add track studs to maintain
39. ake lever lock is set while the engine is running It will also illuminate when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly The lock will return to the unlocked position A WARNING If the parking brake lever lock is partially or entirely engaged while riding the brakes may overheat resulting in brake damage In extreme cases it could cause a fire which could result in serious injury or death Always ensure that the lever lock is completely disengaged before operating the snowmobile 61 PRE RIDE INSPECTIONS Before Starting the Engine i Steering System A WARNING Ice and snow build up may interfere with the steering of your machine result ing 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 y Track A 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 p
40. ake sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide pro tection under normal riding conditions Your snowmobile is not intended for this kind of use Be courteous to oncoming traffic by dimming your headlights and reducing your speed When traveling in a group of snowmobiles don t tailgate follow too closely Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions Be aware of any snowmobile traffic around your vehicle Drive defen sively to avoid accidents Remove the key from the ignition when you leave the snowmobile unattended 21 SAFETY Operator Safety Windchill Temperature Charts The following information is provided to help you determine when tem peratures become dangerous for riding WINDCHILL CHART F Wind Actual Thermometer Reading F Speed 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 MPH Equivalent Temperature F Calm 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30
41. alendar years from date of purchase whichever comes first Tampering with the odometer shall void all warranties service contracts No extensions to coverage under this engine service contract can be given Used snowmobiles are not eligible under this program e Snowmobiles used for commercial purposes or for racing are excluded from coverage Coverage Coverage for second year engine failures due to defects in materials and workmanship will be determined by Polaris in its sole discretion Coverage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes Damage due to accident fire explosion theft or other causes beyond Polaris 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 exclud
42. ange torsion spring to stiffer optional spring see your dealer Revalve rear track shock see your dealer Rides too stiff in rear Check for binding suspension shafts and grease all pivot points Adjust torsion spring preload to achieve proper static sag see page 46 Change torsion spring to softer optional spring see your dealer Check track tension see page 108 Too much weight transfer when climb ing Set static sag see page 46 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Adjust limiter straps see page 49 Too little weight transfer when climb ing Set static sag see page 46 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Adjust limiter straps see page 49 Machine darts from side to side Check ski alignment see page 112 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Set static sag see page 46 Check rail slide replace if worn see page 114 Install Accu Trak dual skags see your dealer Front end pushes Check for worn skags Set static sag see page 46 Check for binding front suspension shafts and steering components grease all pivot points elevate front of machine Increase IFS preload if equipped see page 42 Install single skag see your dealer R
43. at build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle openings and machine speeds to reduce friction on all close fitting machined parts allowing them to break in slowly without damage Use of any lubricants other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris lubricants for your vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the machine 66 OPERATION Engine Break In Oil Injection System Always check and fill the oil tank when refueling See page 71 NOTICE 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 118 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
44. ck to rotate several revolutions TIP It will take longer to warm up the track suffi ciently during colder outdoor temperatures 4 Release the throttle apply the brakes shut off the engine and lower the machine to the ground 5 Grasp the skis by their front loops and move them from side to side to loosen snow and ice 68 OPERATION Fuel A WARNING Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline Always refuel outdoors or in a well ventilated area e 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 e If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time A WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 69 OPERATION Fuel For peak performance Polaris recommends the use of 91 octane or higher fuel Although 87 octane fuel is usable some engine perfor mance will be lost and fue
45. clockwise for a softer ride KA 50 THE PERFECT FIT Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions there are two torque arms that control the movement of the rail beam Prior to the advent of sus pension coupling these torque arms could move independently of each other Rear suspension coupling links the movement of the front and rear torque arms to each other There are two types of rear suspension coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amount of indepen dence between the movement of the front torque arm and the rear torque arm When hitting a bump the front torque arm starts to compress The FRSS links that movement to the rear torque arm causing it to compress and raise the rear suspension up as one allowing the suspension to hit the bump only once and reducing kickback The factory setting is usually adequate for all riders and conditions 51 THE PERFECT FIT Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop RRSS The rear rear scissor stop RRSS couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen dent movement between the rear torque and the front torque arm Adjusting the RRSS either allows more weight to
46. ction Loose nuts and bolts can reduce your snowmobile s reliability and cause needless repairs and down time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the follow ing items on a weekly basis or before any long trip Check suspension mounting bolts for tightness Check rear idler wheel bolts for tightness See page 109 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter strap condition Check rail slide condition See page 114 Check track tension See page 108 Lubricate all rear suspension components See page 83 Check ski runner skag condition See page 113 Check ski spindle bolts for tightness YYYYAYYY YY Check tie rod end nuts for tightness 114 MAINTENANCE Extended Storage Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components See page 118 for the part numbers of Polaris prod ucts Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint The machine should be stored in a dry garage or shed
47. d 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 sec onds 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 Press the button again up to five times to advance the reminder in 50 hour increments 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 38 FEATURES Instrumentation MFD Battery Replacement models with clocks If the clock function of the MFD isn t working properly replace the battery Replacement batteries are available from your dealer l 2 TIP 5 TIP Remove the plenum from the under side of the hood Locate the black battery compart ment It has a red wire and a brown wire with a white stripe It s located about three inches down the main
48. dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at Polaris if additional assistance is needed This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 127 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 required periodic maintenance upon request may result in denial of warranty coverage Use of the recommended Polaris products for lubrication and maintenance as directed by the Owner s manual is highly recommended Should a failure occur during the warranty period resulting from the use of non recommended products warranty coverage may be denied Warranty do
49. drive system Always remove the drive belt from a disabled snowmobile before towing 77 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain replace or repair the emission control devices or systems on your snowmobile Emission Control Label Your snowmobile is equipped at the time of sale with an emission con trol information ECI label and a factory installed emissions informa tion hangtag These items are required by U S Environmental Protection Agency regulations The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover The ECI label should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is avail able to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owner s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty and read the maintenance s
50. e left locknut and tighten the left adjusting bolt If the track runs to the right loosen the idler shaft bolts then loosen the right locknut and tighten the right adjusting bolt 4 After adjustments are com plete tighten the locknuts and torque idler shaft bolts to 35 ft Ibs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment 110 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary il ean 111 MAINTENANCE Steering System Ski Alignment A WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski align ment or camber adjustment See your Polaris dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement between the skis at point X should be 1 8 to 1 4 3 6 mm greater than the measurement at point Y TIP If the skis are misaligned we recommend that your dealer correct the align ment since camber adjustment may also be affected x el ot o gt lt o gt 4 lt A v 112 MAINTENANCE Steering System Ski
51. e machine Towing Do not use the front bumper to pull or drag the snowmobile The front bumper is not designed for this type of use and may detach from the vehicle if force is applied For your safety do not attempt to use a tow hitch until you ve read the following warnings and understand the proper hitch functions A WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used If passengers are to be towed on a tobog gan or sled make sure the pole is at least four feet 1 2 meters long to pre vent any possibility of contact between the snowmobile s track and a person riding in the towed object Braking distances increase when towing loads Slow down to maintain con trol of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damage to the steering components Remove the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary NOTICE Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and
52. ection of your owner s manual You are responsi ble for ensuring that the specified maintenance is performed Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary 78 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and perform service checks as out lined in this manual Record maintenance and service in the Mainte nance Log beginning on page 133 The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles 240 km 500 miles 800 km and 1000 miles 1600 km These inspections should be per formed by a qualified service technician For continued optimum perfor mance and component life continue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to service or make adjust ments to your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfort able performing t
53. ed from coverage Gaskets are covered as are intake and exhaust manifolds excluding paint coverage Electrical coverage is limited to the ECU box coils stator plate and sensors Wiring and other electrical components are excluded from coverage Cooling system coverage is limited to the water pump assembly and components fan fan bearings temperature sensor gasket and seals Non wear related throttle body parts are covered The fuel pump is covered Clutches and related clutch parts including but not limited to the drive belt are excluded from coverage Electrical components are excluded from coverage Gearcases and transmissions are excluded from coverage 129 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 yo
54. eedometer 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 84 MAINTENANCE Lubrication Y Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 79 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 118 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level sur face 2 View the oil level at the sight glass 3 Remove the fill plug 3 and add the 2 recommended oil as needed Do not overfill 4 Reinstall the fill plug making sure it is seated properly 85 MAINTENANCE Lubrication 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 Clean off all metal shavings from the plug 4 Install a new sealing washer on the drain plug The sealing surfaces
55. en top bolts to adjust handlebar angle nf Ta Handlebar Angle 1 Loosen the four bolts on the top of the adjuster block If w necessary pry the blocks l an apart with a screwdriver T 2 Adjust the handlebar forward or rearward to the desired angle Loosen bottom bolts to 3 Tighten the bolts adjust handlebar position 54 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 e Non compliance with government industry requirements e Voiding of warranty e Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service 55 THE PERFECT FIT Traction Products 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 warran ties are void if track damage or failure results from improper or exces sive stud installation or the use of non Polaris traction products See your dealer about installing studs and or carbides NOTICE Always install wear strips before installing studs F
56. enance Log 000ee0es 133 INdOX 4 oe eww see rads bbe vedi ced cee 136 INTRODUCTION Important Notes for Owners and Drivers After reading this manual store it in the snowmobile for convenient ref erence It should remain with the snowmobile when the snowmobile is sold Some of the illustrations and photos used in this manual are general rep resentations Your model may differ Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding clubs When teaching inexperienced operators to ride set up a predetermined course for practice Make sure they know how to drive and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses sponsored by local or state organizations INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam paign We encourage state and provincial governments across the snow belt to adopt rigorous safety training programs that encourage protection of our environment including
57. 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 ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2008 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissio
58. es not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination The following items are excluded from warranty con sideration if the failure was due to wear or not the direct result of a defect Skis Ski wear rods Tracks Slide rails Suspension components Finished and unfinished surfaces Brake components Carburetor Throttle body components Seat components Engine components Clutches and components Drive belts Steering components Hydraulic components Batteries Circuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adju
59. et to zero after refueling Odometer Setting The odometer records the vehicle s total distance traveled since manufacture The odometer cannot be reset FEATURES MILES a a mri ww E MILES 33 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 Set the minutes in the same manner 5 When finished press the MODE button to save the new setting If the MODE button is not pressed within ten seconds the clock will automatically save the new entry 34 FEATURES Instrumentation MFD Digital Display Programs Engine Program The Engine Program automatically displays the engine coolant tempera ture engine hours electrical system voltage level and fuel level if equipped 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 dis play the ambient air temperature and altitude screens Air Temperature if equipped The MFD displays actual air temperature Press and hold the MODE switch for ten seconds to switch between standard and m
60. etric units of measurement Hour Meter The hour meter records the total hours of engine operation since manufacture This meter cannot be reset Engine Temperature i ICO A thermometer measures water temperature I f 1 t giving an indication of engine temperature ENG F 2 a he g8 35 FEATURES Instrumentation MFD Digital Display Programs Engine Program Altitude if equipped The rider can calibrate the altimeter for current atmospheric conditions Altimeter accuracy will be 300 ft 91 m after adjustment TIP TIP 36 Press and hold the MODE switch for ten sec onds to switch between standard and metric units of measurement When ALt displays the program is in the metric mode Enter the Engine Program and select the altimeter display Press and hold the SET button for five seconds 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 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 cal
61. ety Driving in Hilly Terrain A 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 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 18 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed Any servicing that requires operation without a belt must be performed by your dealer Operation of the engine with the belt removed may result in injury or damage to the engine Intake Si
62. ey off Wait for the engine to come to a complete stop Lock the parking brake Open the hood and remove the left side panel Rotate the driven clutch counterclockwise 1 4 turn by hand to ensure forward engagement Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch Turn the wrench clockwise until the sheaves open far enough to remove the belt If the wrench does not turn readily rotate the driven clutch counterclockwise an additional 1 4 turn by hand and try again Grasp the belt at the lower edge and remove it MAINTENANCE Clutch System Drive Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack 2 To ensure satisfactory belt life install belts so they oper ate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt removal procedures 3 Rotate the L wrench counterclockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 4 Remove the L wrench and store it in the tool kit 5 Reinstall the side panel 6 Close and secure the hood Torque Stop Periodically check torque stop clearance 010 030 With clutches in proper alignment the 25 75 torque stop clearance should be 010 asara Mi 030 25 75 mm from the engine case Adjust if necessa
63. g and lubrication will lead to overheating of the slide rail and track causing premature wear damage and failure which can result in serious injury Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating for prolonged periods on ice hard packed surfaces or roads Operating in Deep Snow If the 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 the snowmobile will be able to climb up and over the snow 20 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently and even the most docile condi tions may become dangerous if operators drive improperly If you re new to snowmobiling acquaint yourself with the machine and with what it will and won t do under various conditions Even seasoned driv ers should spend some time getting the feel for a machine before attempting ambitious maneuvers 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 to use your snowmobile know the extent of their operating skills Check to see if they ve taken a snow mobile safety course and have an operator s certificate For their pro tection as well as yours m
64. here s no spark SEE YOUR DEALER No fuel to engine Make sure the fuel valve is on 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 com pression Mixture is too lean A main jet that is too small will cause seizure result ing in loss of power This indicates a major engine problem that must be repaired before operating SEE backfires YOUR DEALER Engine lacks power Fouled or defective Replace the plug s spark plug s Fuel filter loss of e SEE YOUR DEALER high RPM power Incorrect clutching e SEE YOUR DEALER Engine continually Faulty plug s e Change plug s Fuel System Dirt or ice may be in the fuel system deicer should be added to non etha nol fuel at all times for assurance against fuel line icing more than normal pulls to start Incorrect throttle e SEE YOUR DEALER freeplay or faulty switch Engine requires Poor fuel e Replace with fresh winter fuel Not enough fuel get ting to engine SEE YOUR DEALER Engine backfires but fails to start Spark plug wires may be on wrong cylinder Reinstall spark plug wires to the cor responding cylinder 121 TROUBLESHOOTING IQ Switchback Suspension Troubleshooting Problem Solution Rear suspension bot toms too easily Adjust torsion spring preload to achieve proper static sag see page 46 Ch
65. hese tasks yourself contact an authorized Polaris dealer for service NOTICE Hot components can cause damage to plastic Always make sure the exhaust system and engine have cooled before tipping the snowmo bile on its side for service or inspection 79 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions You may need to increase frequency based on riding conditions When inspection reveals the need for replacement parts always use genuine Polaris parts available from your Polaris dealer Item See Frequency Page 7s0 mi 500mi 1000mi 2000 mi Pre 240 km 800 km 1600 km 8200 km Season CLUTCH Clutch Alignment Offset 101 l l l without belt Drive Belt Condition 102 l l l l Clutches 101 c c Cc Belt Tension l l l l Clutch Sheaves 101 l l l l ENGINE COOLING Engine Mounts l l l l Recoil Rope l l l l Engine Torque Stop 105 l l l l Cylinder Head Bolts l l l Cylinder Base Nuts l l l l Ignition Timing BTDC l l l VES System Cc Cc Cc l Coolant Level 91 l l R l Coolant Hose l l l l Heat Exchangers 93 l l l l l Coolant Circulation l l l Coolant Leaks l l l l Spark Plug Condition 88 l l l R l Exhaust Pipe 94 l l Exhaust Retaining 94 l l l l Springs Inspect clean adjust tighten lubricate replace if necessary C C
66. ibrated altitude and 50 ft 15 m will be added to the altitude each time the SET button is pressed Press the MODE button to hold the reading at the adjusted value If it s not pressed within five seconds the gauge will automatically save the new setting FEATURES Instrumentation MFD Digital Display Programs History Program The History Program automatically displays electrical system voltage level and fuel level if equipped While in the History mode press the SET button to view maximum vehicle speed maximum engine rpm or the current service interval set ting 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 maxi mum 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 TIP Due to electrical noise the MFD may occa sionally display MAX MPH RPM values that are not representative of actual values 37 FEATURES Instrumentation MFD Digital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders When the logged hours reaches the designate
67. icates the direction of flow through the fil er 89 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system When operating in loose powder snow check the foam fil ters periodically to remove any accumulation of snow NOTICE 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 All fuel pump service must be performed by an authorized Polaris dealer Do not attempt to service the fuel pump Fuel Filter Fuel Lines See your Polaris dealer for replacement of the fuel filter 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 dete rioration from weather and fuel compounds may occur Replace worn or damaged fuel lines promptly NOTICE Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly 90 MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50 50 mixture of ethylene glycol and distilled water which will provide adequate freeze protection under most conditions If the vehicle will be stored or oper ated at extremely low tempera
68. ill the coolant bottle with properly mixed coolant to the maximum mark 3 Remove the bleed screw from the water outlet manifold and or the thermostat housing Allow the coolant to bleed through the system until it runs out the bleed holes Reinstall the bleed screw into the manifold 4 Add coolant to the coolant bottle to the maximum mark 5 Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air 6 Stop the engine and check the coolant bottle level Fill as required 7 Feel the heat exchangers under the running boards On Switchback models feel the tunnel gripper coolers on both sides If the system is bled properly they ll be warm to the touch If they re not repeat step 5 Lift the front of the machine slightly to assist in the bleeding 8 Replace the pressure cap and carefully lower the front end of the machine 93 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles 3200 km Always allow the engine and exhaust system to cool completely before inspecting A CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine run ning 1 Open the hood and inspect the muffler and pipes for cracks or dam age 2 Check for weak or missing retaining springs or damper support grommets 3 Check f
69. ion Spring Preload To adjust rear torsion spring preload rotate the three position cam using the engine spark plug tool Adjustment is easiest when the cam is rotated from low to medium and then to high Rotating directly from low to high will require significantly more effort Different rate torsion springs are available if a firmer ride is desired See your dealer for more information 48 THE PERFECT FIT Rear Suspension Adjustments Limiter Strap Position Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling If a rider prefers more ski pressure for improved steering performance adjustments can be made to the front limiter straps Tighten the straps to increase ski pressure Loosen the straps to reduce ski pressure SP models have only one limiter strap 1 Remove the nuts and flat washers from the upper limiter straps 2 Relocate the straps to the desired position 3 Reinstall the nuts and washers Tighten securely 49 THE PERFECT FIT Rear Suspension Adjustments Rear Shock Compression Damping Premium Shock Front Track Shock Compression Damping SP Models Turn the adjuster 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 one click then test ride Turn the adjuster clockwise for a stiffer ride e Turn the adjuster counter
70. it to finish loading if necessary Clutch malfunction Inspect clutch components See your dealer Slow easy clutch engage ment e Use fast aggressive throttle to engage clutch 123 WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information con tained 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 con tained in this manual Your dealer is also familiar with Polaris policies and pro cedures and will be happy to assist you When contacting us about parts service or warranty always provide the fol lowing information Serial number Model number Dealer name Date of purchase Details of trouble experienced AU A UN Length of time and conditions of operation 7 Previous correspondence Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris Customer Service United States 1 888 704 5290 Canada 1 204 925 7100 124 WARRANTY Service and Warranty Information Polaris Anti Theft System The Polaris anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines
71. l economy will decrease Do not use lower than 87 octane fuel Do not use fuel containing more than 10 ethanol including E85 NOTICE Operating with obstructed fuel systems will result in serious engine damage Perform maintenance as recommended Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline to prevent 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 118 for the part numbers of Polaris products If you use oxygenated fuel containing ethanol additional alcohol deic ers or water absorbing additives should not be used 70 OPERATION x Oil Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low Visually check for oil in the bottle Add oil before further operation of the snowmobile See page 67 for oil recommendations Low Oil Level Maintaining the proper oil level will prevent system aeration and possi ble loss of pumping action which could result in engine damage This is especially important when the machine is operated in mountainous ter rain NOTICE Operating the snowmobile without
72. l models are equipped with all features shown _ aon Nosepan 7 Skis 8 Front Bumper do not use for 9 pulling or dragging the snow 10 mobile 11 Hood 12 Headlight 13 Windshield Handlebar Operator Seat Taillight Rear Bumper Snow Flap Suspension Track 27 FEATURES 3 Not all models are equipped with all features shown CONAARWN gt 28 Thumbwarmer Switch Electronic Reverse Button Multi Function Display MFD Fuel Filler Cap Ignition Switch MFD Gauge Engine Stop Switch Throttle Control Recoil Starter Handle Hood Hold Down Straps Parking Brake Lock Handlebar Grip Warmer Switch Control Headlight Dimmer Switch Brake Lever FEATURES Cargo Area The maximum weight capacity for the cargo area is 15 lbs 7 kg Install only accessories specifically approved for this model by Polaris Always secure cargo before operating Do not exceed the cargo area weight limit Adjustable Headlights Adjust the headlight beam by moving the adjuster to the left or right Detonation Elimination Technology DET The DET system prevents damage to the engine from detonation by automatically reducing the engine timing and adding fuel whenever the sensors detect detonation You may notice decreased engine RPM and performance when DET is activated but in most cases DET activation is temporary and the timing will return to normal automatically In extreme conditi
73. lean R Replace L Lubricate 80 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 750 mi 500mi 1000mi 2000 mi Pre 240 km 800 km 1600 km 8200 km Season BRAKES Hose Routing l l l l Hose Condition l l l Fluid Leaks l l l l Brake Pads 96 l l l l Brake Disc l l l l Parking Brakes 61 l l l l Brake System 60 96 l Brake Fluid 97 R FUEL MANAGEMENT Idle RPM l l l Throttle Lever 73 l l l l l Oil Pump Lever l l l synchronize Throttle Cable 84 L L L Throttle Position l l l Sensor Fuel Lines 90 l l l l l Fuel Filter 90 R R Oil Filter 89 R R Oil Lines 89 l l l Air Box l l l l l ELECTRICAL Auxiliary Shut Off 64 l l l l l Switch Throttle Safety Switch 72 l l l l l Ignition Switch l l l l l Taillight 64 l l l l l Brakelight 64 l l l l l Headlight 64 l l l l l 81 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 7s0 mi 500mi 1000mi 2000 mi Pre 240 km 800 km 1600 km 8200 km Season CHASSIS Ski Toe Alignment l l l Suspension Mounting l l l l l Bolts Steering Fasteners l l l l Cc Rear Suspension l l l l l Fasteners Suspension Shock Oil l l l l Cooling Fins and l l l l Shroud Drive Shaft Bearing 84 L
74. lencer Do not operate the engine with the intake silencer or filter removed Damage to the engine may occur if the intake silencer or filter are removed Clutches Do not attempt to service the clutches All clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the machine into motion but always operate within safety limits Maneuverability While much control and maneuverability is achieved through the steer ing system and skis maximum control is achieved by the shifting of your body weight Maneuverability will change for lighter operators or machines designed to carry a load 19 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is a requirement for operation of your snowmobile NOTICE Driving in too little snow will result in excessive wear and damage to the slide rail track and or engine A WARNING Inadequate coolin
75. ning 24 SAFETY Safety Decals and Locations Reverse Warning Reverse Warning The reverse warning decal is located on the console either beside the steering post or below the windshield WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while back Reverse Warning ing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Machine stopped and engine at idle push yellow button on LH con trol to reverse Flashing light on dash indicates reverse operation Push button again to return to forward Operation Warning The operation warning decal is also located on the console See page 26 for the text Operation Warning 25 SAFETY Safety Decals and Locations Operation Warning 26 To avoid serious injury or death read and understand all warnings and the Owner s Manual before operation If manual is missing con tact a Polaris dealer for a replacement This vehicle is capable of high speeds Buried objects or uneven terrain can cause loss of control Reduce speed and use extreme caution when operating in unfamiliar terrain Excessive speed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes
76. ns 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 2009 Owner s Manual P N 9921220 600 IQ IQ Shift 136 600 Switchback 600 Dragon Switchback 600 Dragon SP 800 IQ 800 Switchback 800 Dragon Switchback 800 Dragon SP 2 TABLE OF CONTENTS Introduction 6 30 82 tah eS ceo Rie eens 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 This section describes safe vehicle operation and identifies warning decals and their locations POAQLUIES 22S eer SESE tie Calis 27 This section identifies the locations of your snowmobile s controls and features The Perfect Fit 0 000 e eee ee eae 41 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 0000000 58 This section explains procedures that must be performed before riding Operation 65 This section explains proper engine break in operation of features and general operating procedures Maintenance 2000ee0ee ee ees 78 This section defines your role and your dealer s role in your snowmo bile s regular maintenance Polaris Products 2 iis sees eae ee eee 118 Troubleshooting 002200eee eens 119 Warranty 333i a ee oak bette ee 124 Maint
77. ons the DET sys tem retards timing and holds it in a retarded state If this occurs replace the fuel with recommended fuel or see your Polaris dealer for service Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Improper engine modifications Do not modify the engine 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 of power The sensor must be reconnected or repaired to regain full power See your Polaris dealer for service if this occurs TIP The check engine light will flash six times if the sensor fails or becomes dis connected 29 FEATURES Instrumentation MFD Component Identification Item 1 Analog if equipped Digital Gauge o CHECK ENGINE Indicator carb models Low Oil Indicator High Temp Indicator Brake Indicator Reverse Indicator CO N OD aj gt A High Beam Indicator Digital Display Identification Item 1 RPM or Speed Altitude i equipped Service Interva 2 Electrical System Voltage Level 3 MAX Maximum MPH KPH or RPM MPH Miles per hour KPH Kilometers per hour RPM Engine crankshaft revolutions per minute B on a i aa aay a I 4 Air Temp if equipped Engine Temp Degree
78. or loose clamps on the pipe covers 94 MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip To obtain correct chain tension 1 Rotate the driven clutch counter clockwise to move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 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 95 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile See page 60 Brake pads must be replaced when the brake pad material becomes thin ner than the backing plate approximately 1 16 A kit is available for replacing brake pads See your dealer A WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thickness is 2 less than 1 16 1 5 mm Excessive Lever Tra
79. otate RRSS to high position see page 53 Steering is heavy Make sure spindles and all steering components turn freely Check ski alignment see page 112 Check skags and skis for damage Set static sag see page 46 122 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear Burn Diagnosis Causes Solutions Driving at low RPM e Drive at higher RPMs Gear the machine down Check belt deflection Insufficient warm up e 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 between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine performance Check for carburetor and choke synchronization fouled plugs debris in the carburetor s and water ice or dirt in the fuel tank or fuel line Loading machines onto trailers Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the machine completely onto the trailer Push and pull
80. our dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS Initial dealer preparation and setup of your snowmobile is very important in ensuring trouble free operation Purchasing a snowmobile in the crate or without proper dealer setup will void your warranty coverage Warranty Coverage and Exclusions Limitations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for pur poses other than for which it was manufactured The warranty does not cover any dam ages that occur during trailer transit or as a result of unauthorized service or parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the snowmobile due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the snowmobile The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products T
81. pable of traveling at high speeds Use extra caution to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury The warranty on your entire machine is terminated if any equipment has been added or any modifications have been made to increase the speed or power of the snowmobile SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation A 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 ae va
82. peeds Immediately check the spark plug for correct color A CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service TIP The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetor throttle body adjustments Wet Fouled 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 88 MAINTENANCE Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation Torque to 18 22 ft Ibs 24 30 Nm 5 Reinstall the spark plug cap Oil Lines Inspect oil line condition every 1000 miles 1600 km Oil Filter The oil filter is located at the side of the oil tank Have your dealer change the oil filter and bleed the system annually or every 1000 miles 1600 xe km TIP The direction of the arrows ind
83. perly secured away from sharp edges steering linkage moving parts and hot exhaust parts Transporting the Snowmobile Whenever the snowmobile is transported 1 Be sure the fuel cap and oil cap are installed correctly 2 Tie the snowmobile to the transporting unit securely using suitable straps 3 Remove the ignition key to prevent loss Track and Suspension Moderate track tension should be main tained during summer storage The machine should be supported off the ground to allow the track to hang freely 117 POLARIS PRODUCTS Part No Description Engine Lubricants 2870791 Fogging Oil 12 oz Aerosol 2871098 Premium 2 Cycle Engine Oil qt 2871097 Premium 2 Cycle Engine Oil gal 2871240 Premium 2 Cycle Engine Oil 2 5 gal 2871721 Premium Gold Synthetic 2 Cycle Engine Oil qt 2871722 Premium Gold Synthetic 2 Cycle Engine Oil gal 2872347 Premium Gold Synthetic 2 Cycle Engine Oil 2 5 gal 2874438 VES II Synthetic 2 Cycle Engine Oil qt 2874439 VES II Synthetic 2 Cycle Engine Oil gal 2874443 VES II Synthetic 2 Cycle Engine Oil 2 5 gal Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz car
84. r When teaching inexperienced operators to ride set up a predetermined course for practice Make sure they know how to drive and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses 14 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain e Take an avalanche class Travel with experienced people Travel on designated trails l e Make sure each person is equipped with a shovel probe and avalanche beacon You don t have to be snowmobiling on a slope for an avalanche to occur Be aware that all of the snow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in moun tainous terrain Before riding in mountainous terrain call or log on to your local ava lanche advisory to get current weather and snow stability information For more information about avalanche training and avalanche condi tions contact local law enforcement in your area or visit the American and Canadian online avalanche centers at www avalanche org 15 SAFETY Operator Safety Ice and Snow Build up A WARNING Ice and snow build up may interfere with the steering of
85. re on the pivot pin in the direction shown in the illustration 4 Apply a slight amount of throttle A properly functioning switch must shut down the engine 72 OPERATION Throttle Lever A 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 carburetor throttle body to determine what caused the safety switch to activate 3 Test the throttle lever by compressing and releasing it several times The lever and cable must return to the idle position quickly and completely 4 Ifthe throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 Ifthe engine doesn t start take the snowmobile to an authorized Polaris dealer for service Excessive freeplay in the throttle cable may cause 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 m
86. rive 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 Engine performance will be reduced if you continue operating when the high temperature light is on Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine drain the system completely every two years and add a fresh mixture of antifreeze and distilled water This service must be performed when the engine is cold Ask your Polaris dealer to check the coolant when he performs the fall tune up on your snowmobile 92 MAINTENANCE Cooling System Bleeding the Cooling System A CAUTION Steam and hot liquids will cause burns to your skin Never bleed the cooling system or remove the pressure cap when the engine is warm or hot Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part NOTICE If coolant flow becomes restricted or plugged coolant loss air lock or engine damage may result Most cooling systems are equipped with a filter that should be periodically inspected or replaced Perform the bleeding procedure when the engine is cold 1 Position the vehicle so that the top of the tunnel is level Elevate the front of the vehicle slightly if necessary 2 Remove the pressure cap and f
87. roducts such as studs increases the possibility of track dam age 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 Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty 62 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 snowmo bile i Seat Latches If your snowmobile is equipped with a removable seat ensure that the seat latches are securely in place before every use of the snowmobile Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear is found see your Polaris dealer for replacement 63 PRE RIDE INSPECTIONS Start the Engine and Check Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never engage the starter when the
88. rse Refer to the suspension setup label on your snowmobile or see your Polaris dealer for initial suspension setup information Additional adjustments can be made after initial setup Make adjustments to one area at a time so you can evaluate the change For further assistance see your dealer 44 THE PERFECT FIT Rear Suspension Adjustments 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 setup These adjustments are easy to make involve very little time or effort and greatly affect the ride In deep snow a new rail slide will offer improved performance over worn rail slide It can also improve top speed When riding on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are available from your dealer Polaris offers track kits for improved flotation in deep snow See your dealer for assistance Keep the suspension pivot points lubricated This will reduce mois ture 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 114 Track Tension Track adjustment is critical for proper handling Always maintain cor rect tension and alignment Refer to
89. ry Lock the jam nut q at D e fo oc 105 MAINTENANCE Fall Tune Up For maximum performance arrange for a fall service tune up with your Polaris dealer His experienced and trained service technician will keep your machine in peak operating condition Track Maintenance Track Inspection A WARNING Broken track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and support the rear of the snow mobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire length of each rod Bend the track to check for breakage 4 Replace the track if any rod damage is found 106 MAINTENANCE Track Maintenance Track Lubrication A WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended peri ods on ice and other surfaces that have little or no snow for lubrication The slide rail needs snow for lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear If excessive rail
90. s Celsius _ Degrees Fahrenheit 5 Miles Kilometers pipat 6 Hours Trip 1 Trip 2 Trip F Service Label Altitude Label 7 Fuel Level if equipped 7 30 FEATURES Instrumentation MFD Settings With the engine running use the MFD Control Switch to set the MFD display to your preference The rocker switch has a MODE but ton top and a SET button bottom Standard vs Metric The MFD will display either stan dard or metric units of measurement While viewing a screen that displays measurements MPH KPH or tem peratures press and hold the MODE switch until the unit of measure ment 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 read ings 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 press and hold the MODE button for three sec onds When the button is released the new setting becomes active and screen colors change See table below 5 Analog Digital Digital Option Display Display Screen 1 Speed RPM Blue mph Blue Backlight 2 RPM Speed Red Red X100rpm Backlight 31 FEATURES Instrumentation MFD Digital Display Programs Press the
91. sidue To maintain optimum performance clean with non oil based cleaners such as isopropyl alcohol A 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 NOTICE The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum perfor mance 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 101 MAINTENANCE Clutch System Y 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 123 Always carry a spare drive belt for emergency use Store the spare belt on top
92. ssenger Warnings 24 Preload IFS Shock Spring 42 Pre Ride Checklist 58 Pre Ride Suspension Inspection 114 Pressure Cap Warning 23 R Rail Slide Wear 114 Rear Rear Scissor Stop 52 Rear Suspension Adjustments 44 45 Rear To Front Coupling 52 Recoil Rope 004 63 Recommended Maintenance 9 Registration Warranty 126 Reverses sis say s 344 dates wine aes 75 76 Reverse Warning 25 Rider Capacity 13 Riding Apparel 11 Riding Position 10 RRS So ereu ates anie eah 52 S Safety Decals 23 26 Safety Symbols 8 DAG ised daa eto a A ES 46 47 Shock Compression Damping Front Suspension IFS 43 Front Rear Track 50 Shock Valving IFS 43 Signal Words 0 8 137 INDEX S Ski Alignment 112 Ski Pressure 000 49 Ski Skags 00 113 Slide Rail and Track Cooling 67 Snow Conditions 20 Spark Plug Condition 88 Spark Plug Removal 89 Spark Plugs 0 2 87 Speed a oro tan ese A ADIE T 13 Spring Preload IFS Shock 42 Spring Preload Rear 46 47 Starting the Engine 65 Starting the Engine Restarting 65 Steering Inspection Adjustment 111 Steering System
93. stment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 128 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snow mobiles that were Snow Checked through an authorized Polaris dealer during the March April Snow Check promotion The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transfer able 120 days after the original purchase date free of charge through any Polaris snow mobile dealer Coverage on Snow Check units is automatic Although you do not receive a warranty card your dealership should have printed a copy of the warranty reg istration form This form is your proof of warranty Consumer Exclusions e Each repair visit after the first twelve months of standard warranty coverage is subject to a 50 deductible e The free Second Year Engine Service Contract applies to the first 5 000 miles or two 2 c
94. tarter when the engine is running 75 OPERATION Electronic Reverse PERC 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 sec ond then release The engine will automatically reduce RPM and start a reverse rotation A flashing reverse light on the instrument panel will indicate that the transmission is in reverse 4 Apply the throttle slowly to make sure the transmission is in reverse The maximum engine RPM will be 6000 when in reverse TIP If the engine stops running the snowmobile will be in forward gear when it s restarted Disengaging Reverse 1 Stop the snowmobile and leave the engine idling NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running 2 Push the yellow reverse button for one second and release The engine will slow and begin to rotate forward The light on the instrument panel will shut off 3 Apply the throttle slowly to make sure the transmission is in for ward 76 OPERATION Daily Storage At the end of each ride park the snowmo bile 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 th
95. to avoid unexpected obstacles or to stop safely Never consume alcohol or drugs before or while operating this vehi cle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control the vehicle When operating on hard packed snow ice or when crossing roads steering and braking ability are greatly reduced Reduce speed and allow extra space to turn or stop To maintain vehicle control on ice or hard packed surfaces you should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for long periods Do not leave brake engaged for more than five minutes Before starting engine check throttle brake and steering for proper operation Make sure hood is latched Be seated and in posi tion to control the vehicle Oil injection system Use unmixed fuel only Check oil level when refueling FEATURES Not al
96. to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cel lular telephone For added protection carry the following items on your snowmobile at all times Spare Drive Belt e Winter Survival Kit e Extra Set of Spark Plugs e Trail Map e Tow Rope e Owner s Manual e Extra Oil e First Aid Kit e Fuel Deicer Tool Kit 12 SAFETY Operator Safety Rider Capacity Driving 1 Up Some Polaris snowmobiles are designed for a single rider only A decal on the console of these models indicates single rider operation Driving 2 Up Some Polaris snowmobiles are designed for up to two riders A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only Machines designed for two riders should never be operated with more than two people on board When traveling with a passenger it s the driver s responsibility to operate the machine safely Slow down Control becomes more difficult with two people on board More space is required to make turns and longer distances are necessary for stopping Excessive Speed A 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 laws governing snowmobile operation and speed limits Always be alert and pay attention to the trail
97. tridge 2871329 Dielectric Grease Nyogel Coolant 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT 4 Brake Fluid 12 oz 2872893 Engine Degreaser 12 oz 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carb and Throttle Body Cleaner 118 TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two cycle engine repair see your dealer if technical problems arise Problem Probable Cause Solution Erratic engine oper ating RPM during acceleration or load variations Drive clutch binding SEE YOUR DEALER Driven clutch mal function e SEE YOUR DEALER of spec Harsh drive clutch Drive belt worn or e Replace the drive belt engagement too narrow Excessive belt e SEE YOUR DEALER sheave clearance Drive belt turns over Wrong belt for appli e Replace the drive belt cation Clutch alignment out SEE YOUR DEALER Engine mount bro ken or loose Inspect and replace SEE YOUR DEALER Machine fails to move Clutch jammed e Check for twisted belt or broken spring SEE YOUR DEALER Track jammed e Foreign object may be caught or the rail slide melted to the track clips due to lack of lubrication Track may be iced up or frozen to the ground Chaincase sprocket or chain jammed or
98. ts that are covered by this warranty This includes all components whose failure increases the snowmobile engine s emissions Replacing or repairing other components not covered by this warranty is the responsibility of the snowmobile owner The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATE IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law 131 WARRANTY Snowmobile Engine Emissions Limited Warranty This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use
99. tures greater protection may be required Please see your Polaris dealer When adding or changing coolant Polaris recommends using Premium 60 40 anti freeze coolant which is already premixed and ready to use Do not dilute with water Never exceed a 60 antifreeze 40 water mixture See page 118 for Polaris products Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are e Coolant bottle or overflow tank Engine filler neck e Pressure cap e Connecting hoses Always maintain the coolant level between the minimum and maximum marks on the coolant bottle when engine is cold to prevent overheating and serious engine damage NOTICE Operating the snowmobile with insufficient coolant will result in over heating and serious engine damage Always maintain the coolant level as recommended 91 MAINTENANCE Cooling System Coolant High Temperature Indicator Light A CAUTION Steam and hot liquids will cause burns to your skin Never remove the pres sure cap when the engine is warm or hot The high temperature indicator light will illuminate when engine cool ant temperature becomes too hot for safe continued operation of the engine If you must drive your machine after the high temperature indi cator light has come on d
100. ur vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance see page 124 130 WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris standard limited warranty for snowmobiles Polaris Industries Inc warrants that at the time it is first purchased this emissions certified snowmobile engine is designed built and equipped so it conforms with U S Environmental Protection Agency regulations applicable to snowmobile emissions Polaris warrants that the engine is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified snowmobile engine starts on the date when the engine is first purchased and continues for a period of 200 hours of engine operation 4000 kilometers 2485 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This engine emissions limited warranty covers the parts and labor charges for repair or replacement of defective par
101. ur vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the 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 yo
102. ust 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 73 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 72 for more information about the engine stop switch and throttle safety switch SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch Interrupts ignition circuit Throttle Safety Switch Interrupts ignition circuit Tether Switch Option Interrupts ignition circuit 74 OPERATION Electronic Reverse PERC Electronic reverse will activate only if the engine RPM is below 4000 A 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 e Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle e Look behind the vehicle before and while backing e Avoid sharp turns e Apply throttle slowly NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the s
103. vel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops bring the machine to an autho Y rized Polaris dealer for inspec lI 3p tion and adjustment i rp 96 MAINTENANCE Brakes Brake Fluid The brake fluid level can be seen through a plastic sight glass in the brake reservoir If the fluid is sufficient the sight glass will be black If the sight glass is any color other than black add brake fluid Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid See page 118 for the part numbers of Polaris products A WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rap idly absorbs moisture from the air The moisture causes the boiling tempera ture of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury A WARNING Keep the master cylinder cover free of dirt and debris The vent slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function NOTICE Brake fluid will damage decals paint and some plastics Always wipe up spills immediately 97 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action
104. wly until the recoil engages then pull abruptly to crank the engine TIP Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Damage may result 5 Ifthe engine does not start after several attempts slightly depress the throttle no more than 1 4 open while cranking the engine When the engine starts immediately release the throttle A CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running Restarting an Engine If the rider stops the engine by pushing the engine stop switch down restart the engine using the normal starting procedure If the engine fails to start using the normal procedure 1 Push the engine stop switch down to the OFF position 2 Turn the key to the OFF position 3 With both switches OFF squeeze and hold the throttle in the wide open position Crank the engine several times to clear the engine 5 Release the throttle 6 Restart the engine using the normal starting procedure 65 OPERATION Engine Break In No single action on your part is as important to long trouble free machine life as proper break in of a new or rebuilt engine Premix the first tank of fuel with one pint of Polaris injection oil for each five gal lons of fuel This in addition to the lubrication supplied by the injection system will assure proper engine break in NOTICE Excessive he
105. y number in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number Tunnel VIN right side of tunnel Engine Serial Number on recoil housing Key Number SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual indicates the potential for serious injury WARNING A WARNING indicates a potential hazard that may result in serious injury or death CAUTION A CAUTION indicates a potential hazard that may result in minor injury NOTICE A NOTICE indicates a situation that may result in damage to the vehicle SAFETY Operator Safety Follow the recommended maintenance program beginning on page 79 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals A WARNING Driving a snowmobile requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger They will reduce your alertness and slow your reaction time Snowmobiles are ca
106. your machine result ing in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Driving on Slippery Surfaces A WARNING Never attempt an abrupt change of direction when operating on slippery sur faces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces steering and braking control which may result in loss of control and serious injury or death Slow down and use extra caution when operating on slippery surfaces 16 SAFETY Operator Safety 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 A WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may result in brake failure Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system This condition may lead to a sudden loss of brakes and or fire and may result in serious injury or death 17 SAFETY Operator Saf
107. ys check the following items for proper operation before starting the engine Brake Lever Travel Squeeze the brake lever It should move no closer to the n handgrip than 1 2 1 3 cm tie sen A smaller distance indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 98 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 97 A WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always have the brakes serviced at the first sign of sponginess 60 PRE RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking 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 4 2 Parking Brake Lever Lock 3 Master Cylinder Reser voir Cover 1 4 Fluid Level Indicator Lock Engagement To engage the lock squeeze the brake lever tightly and push forward on the lock Hold the lock forward while releasing the brake lever TIP If the brake lever is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break The brake light will illuminate if the parking br

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