Polaris Offroad Vehicle 600 INDY User Manual

600 INDY

800 INDY

Snowmobile Owner's Manual

for Maintenance and Safety

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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.polaris.com for the latest news, new product introductions,

upcoming events, career opportunities and more.

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

recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• RZR® sport vehicles

• VICTORY® motorcycles

• GEM® vehicles

We believe POLARIS sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of

experience have gone into the engineering, design, and development of

your POLARIS vehicle, making it the finest machine we’ve ever

produced.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Your manual

contains instructions for minor maintenance, but information about

major repairs is outlined in the POLARIS Service Manual and should be

performed only by a factory certified Master Service Dealer® (MSD)

technician.

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

total satisfaction. Be sure to return to your dealership for all of your

service needs during, and after, the warranty period.

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The following are trademarks of POLARIS Industries Inc.:

POLARIS® INDY® PERC®

publication is based on the latest product information at the time of publication. Due to

constant improvements in the design and quality of production components, some minor

discrepancies may result between the actual vehicle and the information presented in

this publication. Depictions and/or procedures in this publication are intended for

reference use only. No liability can be accepted for omissions or inaccuracies. Any

reprinting or reuse of the depictions and/or procedures contained within, whether whole

or in part, is expressly prohibited.

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

translations of the original instructions.

Printed in U.S.A.

2016 600 INDY / 800 INDY Owner’s Manual

P/N 9925987

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TABLE OF CONTENTS

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

This section contains helpful information for owners and drivers and

illustrates the location of important identification numbers that should

be recorded in the owner's manual.

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

This section describes safe vehicle operation and identifies warning

labels and their locations.

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

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

features.

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 59

This section includes suspension set-up information and explains how to

make additional suspension adjustments for the perfect riding

experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 71

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

This section explains proper engine break-in, operation of features and

general operating procedures.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

This section defines your role, and your dealer’s role, in your

snowmobile's regular maintenance.

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 122

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 126

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 127

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 140

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

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INTRODUCTION

Important Notes for Owners and Drivers

After reading this manual, store it in the snowmobile for convenient

reference. It should remain with the snowmobile when the snowmobile

is sold.

Some of the illustrations and photos used in this manual are general

representations. Your model may differ.

Follow the maintenance program outlined in this manual. Preventive

maintenance ensures that critical components of the snowmobile are

inspected by your dealer at specific mileage intervals.

You and your dealer must complete the registration form included with

your snowmobile and forward it to us. This completed form is necessary

to ensure warranty coverage.

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

clubs.

When teaching inexperienced operators to ride, set up a predetermined

course for practice. Make sure they know how to drive and control the

snowmobile before allowing them to make longer trips. Teach them

proper snowmobile courtesy, and enroll them in driver’s training and

safety courses sponsored by local or state organizations.

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INTRODUCTION

Preservation of the Environment

POLARIS is committed to supporting an environmental education

campaign. We encourage state and provincial governments across the

snowbelt to adopt rigorous safety training programs that encourage

protection of our environment, including wildlife and vegetation.

Snowmobile clubs and other organizations are working together to

protect our environment. Please support their efforts and operate your

snowmobile with consideration for the protection and preservation of

our environment.

Noise Level

One of the most publicized issues about snowmobiles is noise. The

Society of Automotive Engineers (SAE), the standard-setting body for

snowmobile development, recommends that snowmobiles conform to

prescribed sound levels.

POLARIS snowmobiles are engineered to conform to these SAE

standards. Our muffler systems are designed to reduce noise levels and

must not be altered or removed. The sound of your snowmobile may not

be welcome to non-snowmobilers, so you have a responsibility to

operate your snowmobile with concern for others. We do our part by

manufacturing quieter machines; we ask your help to further reduce the

impact of noise by operating your snowmobile safely and responsibly.

Air Pollution

POLARIS engineers continuously investigate ways to reduce emission

levels of two-stroke engines. We expect our efforts to lead to the

reduction of potential air pollution.

In addition to our technological research, we encourage government

agencies, manufacturers, distributors, dealers, ecologists, and other

interested parties to work together to develop data on environmental

topics.

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INTRODUCTION

Vehicle Identification Numbers

Record your snowmobile’s identification numbers and key number in

the spaces provided. Remove the spare key and store it in a safe place.

Your key can be duplicated only by mating a POLARIS key blank with

one of your existing keys, so if both keys are lost, the ignition switch

must be replaced.

NOTICE: If installing an aftermarket tunnel wrap, do not cover the tunnel

certification, tunnel VIN or emissions certification labels with the wrap.

If the tunnel wrap doesn’t provide an opening for these labels, remove

the section of wrap where the labels are located.

Certification Label

Tunnel VIN

Emissions Certification Label

Vehicle Model Number: ___________________________________________________

Tunnel VIN (right side of tunnel): ____________________________________________

Engine Serial Number (on recoil housing): _____________________________________

Key Number: ____________________________________________________________

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SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual

and on your vehicle. Your safety is involved when these words and

symbols are used. Become familiar with their meanings before reading

the manual.

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in

death or serious injury.

WARNING

A WARNING indicates a hazardous situation that, if not avoided, could result in

death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation that, if not avoided, could result in

minor or moderate injury.

NOTICE

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

The Prohibition Safety Sign indicates an action NOT to take in order

to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be

taken to avoid a hazard.

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SAFETY

Operator Safety

Follow the recommended maintenance program beginning on page 91

of this manual to ensure that all critical components on the snowmobile

are thoroughly inspected by your dealer at specific mileage intervals.

WARNING

Driving a snowmobile requires your full attention. DO NOT drink alcohol or use

drugs or medications before or while driving or riding as a passenger. They will

reduce your alertness and slow your reaction time.

Snowmobiles are capable of traveling at high speeds. Use extra caution to

ensure operator safety. Make sure your snowmobile is in excellent operating

condition at all times. Always check major and vital safety components before

every ride.

All POLARIS snowmobiles are designed and tested to provide safe operation

when used as directed. Failure of 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.

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SAFETY

Operator Safety

Stay Clear of Track

Your snowmobile is propelled by a revolving track that must be partially

exposed for proper operation. Do not stand on the plastic flap.

WARNING! Serious injuries may result if

hands, feet, or clothing become entangled

in the track. Be alert when riding, and

remain properly seated to stay clear of the

track. Never hold the snowmobile up or

stand behind it while warming up the track.

A loose track or flying debris could cause

serious injury or death. We recommend

having your dealer perform all track service

and alignment procedures.

Stay Clear of Engine

Never attempt adjustments with the engine running. Turn off the

ignition, open the side panels or hood, make the adjustment, secure

shields and guards, secure the side panels and hood, and then restart the

engine to check its operation.

WARNING! Serious injury can occur if fingers or clothing contact the moving

parts of an engine. Always stop the engine before attempting adjustments.

Riding Position

Operating a snowmobile requires skill and balance for proper control.

Rider positions may vary with experience and the features available on

some snowmobiles, but under many conditions, the proper position is to

be seated with both feet on the running boards and both hands on the

handlebar grips for proper throttle, brake and steering control.

WARNING! Improper riding position may reduce control and could result in

serious injury or death. Always ride in a position that allows for control of your

vehicle.

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SAFETY

Operator Safety

Riding Apparel

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a

POLARIS vehicle, always wear a helmet that meets or exceeds

established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of

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

granted approval. The approval number and serial

number will also be displayed on the label.

051039

0006.31

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection.

Whenever riding a POLARIS vehicle, always wear shatterproof goggles

or use a shatterproof helmet face shield. POLARIS recommends

wearing approved Personal Protective Equipment (PPE) bearing

markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye

wear is kept clean.

Clothing

Be prepared, be warm and be

comfortable when riding. Be aware of

the weather forecast, especially the

windchill, and dress accordingly. See

the chart on page 20.

WARNING! Avoid wearing loose clothing

or long scarves, which can become

entangled in moving parts and cause

serious injury. Always wear an approved

helmet and eye protection.

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SAFETY

Operator Safety

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and

physical skills. Operators with cognitive or physical disabilities have an

increased risk of loss of control, which could result in serious injury or

death.

Survival Preparation

For your safety, always ride in a group of other snowmobilers. Always

tell someone where you're going and how long you expect to be gone. If

it isn't possible to ride with others, and you must travel into remote

areas, always carry survival equipment that's appropriate to the

conditions you may encounter. Such equipment may include, but is not

limited to: extra clothing, a sleeping bag, a flashlight, food and water, a

signaling mirror, a means of building a fire, and a two-way radio or

cellular telephone.

Always carry the owner’s manual on your snowmobile. For added

protection, purchase and carry the following items on your snowmobile

as well:

• Spare Drive Belt

• Extra Set of Spark Plugs

• Tow Rope

• Winter Survival Kit

• Trail Map

• First Aid Kit

• Tool Kit

• Extra Oil

• Fuel Deicer

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SAFETY

Operator Safety

Rider Capacity

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

passenger on this snowmobile.

Excessive Speed

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

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

Always observe all state and local laws governing snowmobile

operation and speed limits. Always be alert and pay attention to the trail

ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling

about 60 feet (18 m) per second. If you look back for only two seconds,

your snowmobile will travel about 120 feet (36 m). If your speed is 60

MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in

two seconds.

Traveling at night requires extra caution. Check headlight and taillight

to ensure proper operation, and don’t over-drive your headlight beam.

Always be able to bring your snowmobile to a stop in the distance

illuminated by the headlight.

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SAFETY

Operator Safety

Driver Awareness

Slow down when traveling near poles, posts, or other obstacles. Be

especially alert if you're snowmobiling after dark. Always be on the

alert for wire fences. Single strands are especially dangerous, since there

may be a great distance between posts. Guy wires on utility poles are

also difficult to distinguish.

Make sure the way is clear before crossing

railroads and other roads and highways. The

noise of your snowmobile will drown out the

sound of approaching vehicles. Look ahead,

behind, and to both sides before turning or

R R

crossing railroad tracks or highways. Steep

embankments may also hide your view. Always

leave yourself a way out.

Variances in snow depth and/or water currents may result in uneven ice

thickness. You may drown if you break through the ice. Never travel on

frozen bodies of water unless you have first verified that the ice is

sufficiently thick to support the weight and moving force of the

snowmobile, you and your cargo, together with any other vehicles in

your party. Always check with local authorities and residents to confirm

ice conditions and thickness over your entire route. Snowmobile

operators assume all risk associated with ice conditions on frozen bodies

of water.

When teaching inexperienced operators to ride, set up a predetermined

course for practice. Make sure they know how to drive and control the

snowmobile before allowing them to make longer trips. Teach them

proper snowmobile courtesy, and enroll them in driver's training and

safety courses.

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SAFETY

Operator Safety

Avalanches

Snowmobilers should always be properly

trained and equipped before traveling in

mountainous terrain:

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

• Make sure each person is equipped

with a shovel, probe and avalanche

beacon.

You don't have to be snowmobiling on a slope for an avalanche to occur.

Be aware that all of the snow is connected. You may be riding on a flat

slope or snow covered road, but if the snowpack above is unstable

enough you can trigger an avalanche on a steeper slope above you.

Always be aware of snow conditions above you as you travel in

mountainous terrain.

Before riding in mountainous terrain, call or log on to your local

avalanche advisory to get current weather and snow stability

information.

For more information about avalanche training and avalanche

conditions, contact local law enforcement in your area, or visit the

American and Canadian online avalanche centers at

www.avalanche.org.

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SAFETY

Operator Safety

Ice and Snow Build-up

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

snowmobile, resulting in serious injury or death. Keep the underhood area free

of snow and ice.

Before driving, manually turn the skis to the left and right to be sure ice

and snow are not interfering with full left and right steering. If difficulty

is encountered, remove ice and snow build-up that may be obstructing

the steering linkage.

Driving on Slippery Surfaces

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

slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard-

packed snow reduces steering and braking control, which may result in loss of

control and serious injury or death. Slow down and use extra caution when

operating on slippery surfaces.

Inadequate Snow Conditions

Since snow provides the only lubrication for the power slide suspension

and, on liquid cooled models, cooling for the engine, adequate snow

cover is a requirement for operation of your snowmobile.

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

the slide rail, track and/or engine.

WARNING! Inadequate cooling and lubrication will lead to overheating of the

slide rail and track, causing premature wear, damage and failure, which can

result in serious injury. Reduce speeds and frequently drive into fresh snow to

allow adequate cooling and polishing of the slide rail and track surfaces. Avoid

operating for prolonged periods on ice, hard-packed surfaces or roads.

Operating in Deep Snow

If the snowmobile becomes stuck in snow, clear the running board area

of snow, then step down the snow in front of the snowmobile so that

when the throttle is opened, the snowmobile will be able to climb up and

over the snow.

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SAFETY

Operator Safety

Driving Downhill

When riding downhill, shift your weight to the rear of the snowmobile

and reduce your speed to a minimum. Apply just enough throttle to keep

the clutch engaged, allowing the engine's compression to help slow the

snowmobile and keep it from rolling freely downhill.

WARNING! When driving on long downhill stretches, pump the brakes. Riding

the brakes may cause the brake system to overheat, which may result in brake

failure. Excessive or repetitive use of the brakes for high speed stops will also

cause an overheated brake system. This condition may lead to a sudden loss of

brakes and/or fire and may result in serious injury or death.

Driving in Hilly Terrain

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

balance and snowmobile rollover, causing serious injury or death. Use caution

and good judgement when driving in hilly terrain.

Use extra caution when operating in hilly terrain. If climbing a hill is

unavoidable, keep your weight low and forward. If you must cross the

face of a slope, keep your weight on the uphill side of the snowmobile to

maintain proper balance and avoid possible roll-over.

Slow down when reaching the crest of a hill. Be prepared to react to

obstacles, sharp drops or other people or vehicles that may be on the

other side of the hill.

If you're unable to continue up a hill, turn the snowmobile downhill

before it loses momentum. If this isn't possible, spin the track just

enough to dig in to prevent it from rolling back down the hill. Stop the

engine and set the parking brake (if equipped). Keeping away from the

downhill side of the snowmobile, pull the rear of the snowmobile

around and point the front end and skis downhill. Remount the

snowmobile, restart the engine, release the parking brake, and descend

the hill carefully.

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SAFETY

Operator Safety

Drive Belt

Do not operate the engine with the drive belt removed.

Any servicing that requires operation without a belt must be performed

by your dealer.

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

damage to the engine.

Intake Silencer

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

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

removed.

Clutches

Do not attempt to service the clutches.

All clutch service must be performed by your dealer. The clutch is a

complex mechanism that rotates at high speeds. Each clutch is

dynamically balanced before installation. Any tampering may disrupt

this precision balancing and create an unstable condition.

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time,

especially overnight, always make sure the skis and track are loosened

from ice and snow before attempting to drive. Apply the throttle with

enough authority to put the snowmobile into motion, but always operate

within safety limits.

Maneuverability

While much control and maneuverability is achieved through the

steering system and skis, maximum control is achieved by the shifting

of your body weight. Maneuverability will change for lighter operators

or snowmobiles designed to carry a load.

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SAFETY

Operator Safety

Driving Responsibly

Every snowmobile handles differently, and even the most docile

conditions may become dangerous if operators drive improperly. If

you're new to snowmobiling, acquaint yourself with the snowmobile

and with what it will and won't do under various conditions. Even

seasoned drivers should spend some time getting the feel for a

snowmobile before attempting ambitious maneuvers.

• A snowmobile depends on the rider's body position for proper

balance in executing turns, traversing hills, etc. Always start on a

smooth, level area to begin building your operating experience.

• Before allowing someone else to use your snowmobile, know the

extent of their operating skills. Check to see if they've taken a

snowmobile safety course and have an operator's certificate. For their

protection, as well as yours, make sure they take a snowmobile safety

course. Everyone can benefit from the course.

• Don't “jump” your snowmobile over large drifts or similar terrain.

Jumping may injure your back because of spinal compression that

could occur when the snowmobile impacts the ground. The seat and

suspension of your snowmobile have been designed to provide

protection under normal riding conditions. Your snowmobile is not

intended for this kind of use.

• Be courteous to oncoming traffic by dimming your headlights and

reducing your speed.

• When traveling in a group of snowmobiles, don't tailgate (follow too

closely). Leave enough distance between snowmobiles to provide

ample stopping room and to provide protection from flying snow and

debris. Allow even more distance when driving on slippery surfaces

or when driving in darkness or other low visibility conditions. Be

aware of any snowmobile traffic around your vehicle. Drive

defensively to avoid accidents.

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

unattended.

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SAFETY

Operator Safety

Windchill/Temperature Charts

The following information is provided to help you determine when

temperatures become dangerous for riding.

WINDCHILL CHART (°F)

Wind

Speed

Actual Thermometer Reading (°F)

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

Equivalent Temperature (°F)

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

-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63

40 35 30 25 20 15 10

MPH

Calm 40 35 30 25 20 15 10

36 31 25 19 13

34 27 21 15

32 25 19 13

30 24 17 11

-4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72

-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77

-2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81

-4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84

-5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87

-7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89

29 23 16

28 22 15

28 21 14

27 20 13

26 19 12

25 18 11

25 17 10

-1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91

-2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93

-3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95

-3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97

-4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98

Frostbite in >> 30 min. 10 min. 5 min.

WINDCHILL CHART (°C)

Wind

Speed

Actual Thermometer Reading (°C)

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

Equivalent Temperature (°C)

Km/h

Calm

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

-4 -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57

-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62

-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65

-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67

-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69

-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70

-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72

-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73

-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74

-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75

-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76

-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

Frostbite in >> 30 min. 10 min. 5 min.

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SAFETY

Safety Labels and Locations

Warning labels have been placed on the snowmobile for your protection.

Read and follow the instructions of the labels and other warnings on the

snowmobile carefully. If any of the labels depicted in this manual differ

from the labels on your snowmobile, always read and follow the

instructions of the labels on the snowmobile.

If any label becomes illegible or comes off, contact your POLARIS

dealer to purchase a replacement. Replacement safety labels are

provided by POLARIS at no charge. The part number is printed on the

label.

Clutch Warning/Belt Removal

This warning label is found on the oil bottle:

WARNING

Do not operate engine with hood or side

panels open.

Do not attempt adjustment with engine

running.

Do not operate engine with the clutch

guard removed.

Never run engine with drive belt removed.

Never service clutches yourself. See your

dealer.

Clutch Warning/Belt Removal

BELT REMOVAL - ALL UNITS

1. For electric reverse models, engine

must be stopped in forward to allow clutch opening.

2. Install L-wrench from the tool kit into the open threaded hole in the driven

clutch.

3. Turn the L-wrench clockwise to open the sheaves and replace the belt.

Return the L-wrench to the tool kit.

SEE OWNER’S MANUAL FOR SHEAVE WIDTH ADJUSTMENT

PROCEDURE.

7176327

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SAFETY

Safety Labels and Locations

No Passenger Warning/Fuel Recommendation Label

WARNING

This vehicle is designed for operator only. NO PASSENGER

FUEL RECOMMENDED

91+ OCTANCE WITHOUT ETHANOL

For maximum performance see decal on left hand side panel for proper gauge

setting.

7178713

Reverse Warning

WARNING

No Passenger Warning/Fuel

Recommendation Label

Reverse operation, even at low speeds,

can cause loss of control resulting in

serious injury or death. To avoid loss of

control, always:

• Look behind before and while backing

up.

• Avoid sharp turns.

• Shift to or from reverse only when

stopped.

• Apply throttle slowly.

NOTE: For more information, see

Owner's Manual.

Reverse Warning

If electric reverse:

• Machine stopped and engine at idle, push yellow button on LH control to

reverse. Flashing light on dash indicates reverse operation.

• Push button again to return to forward.

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SAFETY

Safety Labels and Locations

Track Warning

Hot Surface Warning

WARNING

Stay clear of track. Do not sit on seat

back. Entanglement with the track or a

fall from seat back can result in severe

injury or death.

7172519

Hot Surface Warning

WARNING

Hot Surface

Do Not Touch

Burns may result. Entire top of tunnel

may be hot. Install only accessories

specifically approved for this model by

POLARIS.

Track

Warning

7174929

Pressure Cap Warning

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

models:

WARNING

Do not open hot. Test or replace when changing coolant. Press down and turn to

release cap. 13 PSI

7170063

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SAFETY

Safety Labels and Locations

Operation Warning

WARNING

• To avoid serious injury or death, read and understand all warnings and the

Owner's Manual before operation. If manual is missing, contact a POLARIS

dealer for a replacement.

• This vehicle is capable of high speeds. Buried objects or uneven terrain can

cause loss of control. Reduce speed and use extreme caution when

operating in unfamiliar terrain.

• Excessive speed, especially at night or with limited visibility, can result in

insufficient time for you to react to terrain changes, to avoid unexpected

obstacles, or to stop safely.

• Never consume alcohol or drugs before or while operating this vehicle.

• In an emergency, push down the Auxiliary Shut-Off Switch, located on the top

of the throttle control assembly, to stop the engine. Then pull the brake lever

to stop.

• Always wear an approved helmet, eye protection, and adequate clothing

while operating this vehicle.

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

requirements.

(continued on next page)

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SAFETY

Safety Labels and Locations

Operation Warning

• When operating with a passenger (on approved models only) reduce speed

and allow extra space for steering and stopping. A passenger reduces your

ability to control the vehicle.

• When operating on hard-packed snow, ice, or when crossing roads, steering

and braking ability are greatly reduced. Reduce speed and allow extra space

to turn or stop.

• To maintain vehicle control on ice or hard-packed surfaces, you should have

a proper balance of ski carbides to track studs. See Owner's Manual for

proper use of traction products.

• Repeated stops from high speed may cause fading or sudden loss of braking

ability.

• Parking brake may relax when used for long periods. Do not leave brake

engaged for more than five minutes.

• Before starting engine, check throttle, brake, and steering for proper

operation. Make sure hood and side panels are latched. Be seated and in

position to control the vehicle.

Oil injection system: Use unmixed fuel only. Check oil level when refueling.

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FEATURES

1. Nosepan

2. Skis

3. Front Bumper

4. Hood

10. Taillight

11. Rear Bumper

12. Snow Flap

13. Suspension

14. Track

5. Headlight

6. Windshield (accessory)

7. Handlebar

8. Fuel Filler Cap

9. Operator Seat

15. Side Panel

16. Side Panel Strap

17. Side Panel Fasteners

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FEATURES

1. Instrument Cluster (Digital/Analog Gauge shown)

2. Ignition Switch

3. Engine Stop Switch

4. Recoil Starter Handle

5. Brake Lever

6. Parking Brake Lock

7. Handlebar Grip Warmer Switch

8. Thumbwarmer Switch

9. Tool Kit/Storage Bag

10. Electronic Reverse Button

11. MODE/SET Switch

12. Headlight Dimmer Switch

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FEATURES

Adjustable Headlights

Move the headlight adjuster to the

left to adjust the headlight beam

upward. Move the adjuster to the

right to adjust the beam

Down

downward.

Cargo Storage

Cargo Area

The maximum weight capacity for

the cargo area is 15 lbs. (7 kg).

Always secure cargo before

operating. Do not exceed the

weight limit.

Accessories

POLARIS offers a wide range of accessories for your snowmobile to

help make each ride more enjoyable.

Use only POLARIS parts and accessories on your POLARIS

snowmobile. Use of unapproved parts and accessories may result in:

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others

This applies, but is not limited to the following areas: brakes, clutches,

fuel systems, and exhaust systems. Exhaust systems are critical safety

areas that must use approved POLARIS parts. Please see your

POLARIS dealer for service.

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FEATURES

Fuel Type Selection

Whenever using ethanol, MTBE or other forms of oxygenated

gasolines, the fuel type designation setting must be changed to “ETH” in

the gauge. When using the recommended 91 non-ethanol gasoline,

always select the “91-NON” setting.

Whenever in doubt of your fuel

purchase, use the “ETH” setting

as a safeguard.

Use the following procedure to

change the fuel type designation

in the gauge. Refer to the fuel

type selection label located inside

the left side panel.

100

Digital/Analog Gauge

1. Start the engine.

120

140

160

MPH

¹0⁰

MODE

2. Lock the parking brake.

3. Press and release the MODE

button until “FUEL” is

displayed in the lower section of the gauge.

4. Press and hold the SET switch on the left handlebar until the desired

fuel type is displayed in the center of the screen.

Multi-Function Display (MFD)

1. Start the engine.

2. Lock the parking brake.

3. Press and release the

SELECT button or SET

switch until “FUEL” is

displayed in the lower section

of the gauge.

4. Press and hold the SELECT

button or SET switch until the

desired fuel type is displayed

in the center of the screen.

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FEATURES

Detonation Elimination Technology (DET)

The DET system prevents damage to the engine from detonation by

going into an engine protection mode whenever the DET system is

active.

When excessive detonation is detected,

the check engine light will illuminate

and you may notice decreased engine

performance and RPM when the DET

system is activated. In most cases this is

ODO

88888

temporary and the operator does not

need to take any action. The engine will

return to its normal performance

automatically.

Digital/Analog Gauge

If severe detonation occurs, the check

engine light will begin to flash steadily

and the gauge indicator will read “dET”

(see illustration). The engine will enter

a limp home mode and RPM will be

limited to 6500 RPM. The engine will

remain in this mode until it is shut

down and restarted.

MFD

Check Engine Light

Indicates

Excessive detonation detected

Severe detonation detected, RPM will be limited

Solid or Flickering

Steady Flashing

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FEATURES

Detonation Elimination Technology (DET)

The most likely causes of severe detonation are outlined in the

troubleshooting table below.

DET Troubleshooting

Cause of DET Activation

Poor quality fuel

Solution

Replace with higher quality fuel

Incorrect ethanol/non-ethanol fuel

type setting

Verify correct fuel type setting on

gauge

Low fuel/no fuel in tank

Water in fuel

Refuel with recommended fuel

Replace with recommended fuel

Plugged fuel filter or tank pick-up sock See your POLARIS dealer for service

Alcohol-based fuel additive used with Do not add deicers or additives that

Ethanol fuel

contain any form of alcohol while

using up to 10% Ethanol fuel

Improper engine modifications

Do not modify the engine

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FEATURES

Security System (Ignition Lock System)

Your snowmobile has an optional security function that can be activated

by an authorized POLARIS dealer. If you have this feature activated,

you can lock the ignition to prevent unauthorized use when leaving the

snowmobile unattended. A locked system will limit engine speed to

3000 RPM, which prevents clutch engagement, and the snowmobile

will not move when throttle is applied.

If you wish to use this system, see page 38 (Digital/Analog) or page 51

(MFD) for security system activation and operating instructions.

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FEATURES

Engine Overheat Indicators

The over-temperature

indicator in the instrument

cluster will illuminate when

the engine is overheating.

Take action to cool the

engine. See Engine-Cooling

Actions below.

The indicator will flash when

engine temperature reaches

critical levels. Stop the engine

immediately.

Digital/Analog Gauge

A flashing indicator indicates

continued operation could

result in serious engine

damage. The system will

automatically reduce engine

power and create a misfire

condition. Stop the engine

immediately. Allow the

engine to cool down.

MFD

NOTE: If engine overheating seems to be caused by something other than

poor cooling conditions, see your dealer for service.

Engine-Cooling Actions

If the engine is overheating, promptly take action to cool the engine.

• Drive in loose snow.

• View the coolant level. Do not open the pressure cap while the engine

is hot. Add coolant if the level is low.

• Stop the engine and allow it to cool down.

NOTICE: If you must continue to operate while the indicator light is illuminated,

drive slowly and stop the engine frequently to allow it to cool down.

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FEATURES

Instrument Cluster (Digital/Analog)

The instrument cluster contains the speedometer, indicator lamps,

MODE button and rider information center.

NOTICE: Certain products will damage the lens and other plastic surfaces. Do

not use alcohol to clean the instrument cluster. Immediately clean off

any gasoline that splashes on the instrument cluster.

Indicator

Lamps

Speedometer

Rider

Information

Center

MODE

Button

Speedometer

The speedometer displays vehicle speed in either miles per hour (MPH)

or kilometers per hour (km/h).

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FEATURES

Instrument Cluster (Digital/Analog)

Indicator Lamps

Lamp

Indicates

Condition

When standard mode is selected, speed

displays in miles per hour.

Vehicle Speed

When metric mode is selected, speed

displays in kilometers per hour.

Reverse

This indicator flashes when the

transmission is in reverse. See page 87.

High Beam

Parking Brake

The high beam indicator illuminates when

the lights are set to high beam.

This indicator illuminates when the parking

brake is engaged. It will also illuminate

when the service brake is in use. See page

75.

Low Oil

The low oil indicator light may flicker at

times due to oil movement in the bottle, but

when the light comes on and remains on

while at idle, add the recommended oil

before further operation. See page 84.

Over-Temperature

This indicator illuminates to alert the

operator that the engine is overheating. The

operator should take action to cool the

engine. See page 33. If the indicator

flashes, continued operation could result in

serious engine damage. Stop the engine

immediately.

Check Engine

This indicator appears if an EFI-related fault

occurs. Do not operate the snowmobile if

this warning appears. Serious engine

damage could result. See your dealer. See

page 57 for diagnostic code definitions.

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FEATURES

Instrument Cluster (Digital/Analog)

Rider Information Center

The information center can be controlled by either the MODE button on

the instrument cluster or by the MODE/SET switch on the left

handlebar. Setting changes must be made with the engine running or

with the vehicle powered by an external DC power supply connector.

Use the MODE button or the MODE switch to toggle through the

available modes. Use the SET switch on the handlebar to save changes.

The information center is set to display standard units of measurement

at the factory. To change to metric, see page 37.

MODE

SET

MODE/SET Switch

MODE

Button

Information

Display

Trip 12 RPM

ODO

Odometer/Engine Hour

Display

Information Display Area

This area displays either engine speed, engine temperature or maximum

vehicle speed.

Odometer/Engine Hour Display

This area displays the odometer, trip meters and engine hours.

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FEATURES

Instrument Cluster (Digital/Analog)

Rider Information Center

Display Units (Standard/Metric)

The display can be changed to display either standard or metric units of

measurement. While in the engine temperature display, press and hold

the MODE button to change units.

Standard Display

Miles

Fahrenheit

Metric Display

Kilometers

Celsius

Distance

Temperature

Odometer Mode

The odometer records and displays the distance traveled by the vehicle.

Trip Meter Mode

The trip meter records the distance traveled by the vehicle if reset before

each trip. To reset, select the trip meter mode. Press and hold the MODE

button until the meter resets to zero. In the Rider Information Center, the

trip meter display contains a decimal point, but the odometer displays

without a decimal point.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Tachometer Mode

The engine RPM is displayed digitally.

Tip: Small fluctuations in the RPM from day to day may be normal because of

changes in humidity, temperature and elevation.

Fuel Selection Mode

With the brake engaged, toggle to the fuel

selection mode to view or change the fuel

type designation. The display shows the

Trip 12 RPM

ODO

setting chosen by the operator to indicate

the type of fuel in the fuel tank. See page

29 for more information.

Trip 12 RPM

ODO

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FEATURES

Instrument Cluster (Digital/Analog)

Rider Information Center

Security System (Ignition Lock System)

This system is an optional feature and will not function until it has been

activated by your authorized POLARIS dealer. If you have this feature

activated, you can lock the ignition to prevent unauthorized use when

leaving the snowmobile unattended. A locked system will limit engine

speed to 3000 RPM, which prevents clutch engagement, and the

snowmobile will not move when throttle is applied.

If you wish to use this feature, you must complete all four tasks on the

following pages to have your system activated and to change the

security code to one of your own choosing.

First Time Use of Your Security System

Perform all tasks in the order shown if you wish to activate

and use the optional security system.

TASK 1: Activate the security system

See your authorized POLARIS dealer to have the optional security system

feature activated in the electronic control unit (ECU).

TASK 2: Lock the System the First Time

1. Start the engine and lock the parking brake.

2. Press and hold the MODE and SET buttons for 3

seconds, then release. SECURE OFF should be

displayed. If not, repeat this step.

3. Wait until ENTER displays, then press and

release SET to advance the digit. When “0” is

displayed, press and release MODE to accept

the digit. TIP: If the ENTER screen exits due to

inactivity, repeat step 2.

4. Press and release SET to advance the second

digit. When “0” is displayed, press and release

MODE to accept the digit.

5. Press and release SET to advance the third digit.

When “0” is displayed, press and release MODE

to accept the digit.

6. After accepting the third digit, view the display

screen. SECURE ON displays if the system locks.

NOTE: The system is now locked.

7. You must now unlock the system. Proceed

immediately to TASK 3.

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FEATURES

Instrument Cluster (Digital/Analog)

Rider Information Center

Security System (Ignition Lock System)

First Time Use of Your Security System

TASK 3: Unlock the System

1. When the engine is running, the

display will alternate between

SECURE ON and ENTER. Wait until

ENTER displays, then press and

release SET to advance the digit.

When “0” is displayed, press and release MODE to accept the digit.

2. Press and release SET to advance the second

digit. When “0” is displayed, press and release

MODE to accept the digit.

3. Press and release SET to advance the third digit.

When “0” is displayed, press and release MODE

to accept the digit.

4. After accepting the third digit, view the display

screen. SECURE OFF displays if the system

unlocks.

NOTE: The system is now unlocked.

5. You must now enter a new security code. Proceed immediately to TASK 4.

TASK 4: Enter Your New Security Code

1. Immediately after locking and unlocking the system, and while SECURE

OFF is displayed, press and release the MODE button to bring up the

ENTER screen.

2. When ENTER displays, use the SET and MODE buttons to select and

accept each digit of a new personal security code.

3. After accepting the third digit, view the display

screen. CODE SET will display if the system

accepted your new code. You will not see this

display again.

NOTE: Your new code is now set. The system is

NOT locked.

4. Record your new security code in a safe place for future reference.

Record your new personal security code here: __________________

TIP:If you lose your personal security code, see your dealer to have the code

reset to “000”. Then perform TASK 2 through TASK 4 to change the code

to one of your own choosing.

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FEATURES

Instrument Cluster (Digital/Analog)

Rider Information Center

Security System (Ignition Lock System)

Locking the System With Your Personal Security Code

1. Start the engine and lock the parking brake.

2. Press and hold the MODE and SET buttons

for 3 seconds, then release. SECURE OFF

should be displayed. If not, repeat this step.

3. Wait until ENTER displays, then press and

release SET to advance the digit. When the

first digit of your security code is displayed,

press and release MODE to accept the digit.

TIP:If the ENTER screen exits due to inactivity, repeat

step 2.

4. Continue to use SET and MODE to select

and accept the remaining two digits of the

code.

5. After accepting the third digit, view the dis-

play screen. SECURE ON displays if the

system locks. Engine speed is now limited

and the snowmobile cannot be driven.

TIP:When the engine is running, the display will

alternate between SECURE ON and ENTER.

6. If BAD CODE displays, the screen will

then return to the ENTER screen. Repeat

steps 3-5 to re-enter the security code.

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FEATURES

Instrument Cluster (Digital/Analog)

Rider Information Center

Security System (Ignition Lock System)

Unlocking the System With Your Personal Security Code

1. When the engine is running, the display will

alternate between SECURE ON and

ENTER. Wait until ENTER displays, then

press and release SET to advance the digit.

When the first digit of your security code is

displayed, press and release MODE to

accept the digit.

TIP:When the system is locked and engine temperature is above 120° F (49°

C), the correct password must be entered within 60 seconds or the engine

will shut down.

2. Continue to use SET and MODE to select

and accept the remaining two digits of the

code.

3. After accepting the third digit, view the

display screen. SECURE OFF displays if

the system unlocks.

4. Re-enter your code if BAD CODE displays.

NOTE: The system is now unlocked.

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FEATURES

Instrument Cluster (Digital/Analog)

Rider Information Center

Security System (Ignition Lock System)

Changing to a New Security Code

Any time you wish to change your current security code to a new code,

perform TASK 2 through TASK 4 of the First Time Use of Your

Security System procedure beginning on page 38. Instead of using the

factory default code “000” in TASK 2 and TASK 3, use your current

security code.

Security System Access Quick Reference

Now that you have become familiar with the procedure for locking and

unlocking the system, use the chart below as a quick reference.

Security System Access Quick Reference Chart

Action

Result

Start engine + Lock

parking brake + Press

and hold both MODE +

SET

Displays ENTER (to lock the system)

Press SET

Advances a digit on the ENTER screen

Press MODE

Accepts a digit and displays the next digit position (if

any remain) on the ENTER screen

Opens ENTER screen if MODE is pressed

immediately after locking and unlocking the system

(to change your security code)

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FEATURES

Instrument Cluster (Digital/Analog)

Rider Information Center

Diagnostic Display Mode

The diagnostic display mode is for informational purposes only. Please

see your POLARIS dealer for all major repairs.

If a system error occurs, the check engine indicator will illuminate. Do

not stop the engine if you want to view an error code. When the engine

is stopped, any codes are stored in the history of the electronic control

unit (ECU). As long as the engine is not stopped, codes can be retrieved

by entering the diagnostic display mode.

Use the following procedure to view error codes.

1. Do not stop the engine.

2. Lock the parking brake.

Suspect Parameter

Number (SPN)

3. Press and release the MODE

button or MODE switch to

toggle to the diagnostic display

mode. If a code exists, two

numbers will appear in the

display (see illustration). The

check engine indicator will

begin to flash.

Failure Mode

Indicator (FMI)

Error Code Displays

Number Type

Display Location

Indication

Suspect Parameter

Number (SPN)

(2-6 digits)

Information

Display

Indicates which component is

generating the fault code

Failure Mode

Indicator (FMI)

(1-2 digits)

Odometer

Display

Indicates fault mode condition,

such as open or short circuit

4. More than one fault may be active. Press and hold the MODE

button or MODE switch for two seconds to toggle to the next code.

Repeat until all codes are retrieved.

5. Press and release the MODE button to exit the mode.

6. See page 57 for code definitions and failure descriptions.

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FEATURES

Instrument Cluster (MFD)

Rider Information

Center

Check Engine

Indicator

High Beam

Indicator

Over-

Temperature

Indicator

Park Brake

Indicator

Reverse

Indicator

Low Oil

Indicator

SELECT

Button

MODE

Button

The instrument cluster

contains indicator lights

and the rider information

center. The information

center can be controlled by

either the MODE and

SELECT buttons on the

instrument cluster or by the

MODE/SET switch on the

left handlebar.

MODE

SET

MODE/SET Switch

NOTICE: Certain products will damage the lens and other plastic surfaces. Do

not use alcohol to clean the instrument cluster. Immediately clean off

any gasoline that splashes on the instrument cluster.

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FEATURES

Instrument Cluster (MFD)

Indicator Lights

Check Engine Indicator

This indicator appears if an EFI-related fault occurs. Do not operate the

snowmobile if this warning appears. Serious engine damage could

result. See your dealer. See page 57 for diagnostic code definitions.

Over-Temperature Indicator

This indicator illuminates to alert the operator that the engine is

overheating. The operator should take action to cool the engine. See

page 33. If the indicator flashes, continued operation could result in

serious engine damage. Stop the engine immediately.

Low Oil Indicator

The low oil indicator light may flicker at times due to oil movement in

the bottle, but when the light comes on and remains on, add the

recommended oil before further operation. See page 84.

High Beam Indicator

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

beam.

Parking Brake Indicator

This indicator illuminates when the parking brake is engaged. It will

also illuminate when the service brake is in use. See page 75.

Reverse Indicator

This indicator flashes when the transmission is in reverse. See page 87.

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FEATURES

Instrument Cluster (MFD)

Rider Information Center

The rider information center is located in the instrument cluster. The

center displays vehicle speed, engine speed, odometer, resettable trip

meters (2), total engine hours of operation, engine temperature and

diagnostic display mode.

Setting changes must be made with the engine running or with the

vehicle powered by an external DC power supply connector.

The information center is set to display standard units of measurement

for distance and temperature. To change to metric units, see page 50.

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FEATURES

Instrument Cluster (MFD)

Rider Information Center

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

or vehicle speed (whichever is not displayed in the speed display),

engine temperature and maximum vehicle speed. To change the

display, see page 48.

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

speed or engine speed. To change the display, see page 48.

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

Trip A, Trip B and engine hours. To change the display, see page 49.

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

low.

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

and play back engine speed, vehicle speed and throttle position

sensor information for up to three minutes. The playback icon

flashes while recording. See page 49.

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FEATURES

Instrument Cluster (MFD)

Rider Information Center

Speed Display Area

The speed display area displays either vehicle speed or engine speed.

Vehicle speed is displayed in either miles per hour (MPH) or kilometers

per hour (km/h). Engine speed is displayed in revolutions per minute

(RPM).

1. To change which item displays, first make sure the information

display area is set to display either engine speed or vehicle speed.

2. Press and hold the mode button (on the instrument cluster) or the

mode switch (on the left handlebar) for three seconds.

Information Display Area

This area displays either engine speed or vehicle speed (whichever is

not displayed in the speed display), engine temperature and maximum

vehicle speed. To change the display, press and release the MODE

button or the MODE switch until the desired item is displayed.

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FEATURES

Instrument Cluster (MFD)

Rider Information Center

Odometer/Engine Hour Display Area

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

hours meter.

The odometer displays the total distance traveled by the vehicle since

manufacture. Each trip meter records the distance traveled by the

vehicle on a trip if the meter is reset before each trip. The engine hour

meter displays the total hours the engine has been in operation since

manufacture.

To change the display, press and release the SELECT button or the SET

switch until the desired item is displayed.

To reset a trip meter, press and hold the SELECT button or the SET

switch until the meter resets to zero.

Playback Function

The playback function allows the rider to record and play back engine

speed, vehicle speed and throttle position sensor information for up to

three minutes.

1. To begin recording, simultaneously press and hold the MODE and

SELECT buttons on the instrument cluster for three seconds. The

playback indicator will flash while the instrument cluster is

recording.

2. To play back the recorded data, stop the vehicle and wait for engine

speed to drop below clutch engagement.

3. Simultaneously press and release the MODE and SELECT buttons

on the instrument cluster.

4. Applying the throttle will clear the display and return the instrument

cluster to normal operation.

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FEATURES

Instrument Cluster (MFD)

Rider Information Center

Standard/Metric Display

The odometer and temperature displays can be viewed in either standard

or metric units of measurement. Both displays change if units are

changed. The new settings will remain until changed by the operator.

Change Method 1

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

temperature displays.

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

change.

Change Method 2

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

odometer displays.

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

change.

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FEATURES

Instrument Cluster (MFD)

Rider Information Center

Security System (Ignition Lock System)

This system is an optional feature and will not function until it has been

activated by your authorized POLARIS dealer. If you have this feature

activated, you can lock the ignition to prevent unauthorized use when

leaving the snowmobile unattended. A locked system will limit engine

speed to 3000 RPM, which prevents clutch engagement, and the

snowmobile will not move when throttle is applied.

If you wish to use this feature, you must complete all four tasks on the

following pages to have your system activated and to change the

security code to one of your own choosing.

First Time Use of Your Security System

Perform all tasks in the order shown if you wish to

activate and use the optional security system.

TASK 1: Activate the security system

See your authorized POLARIS dealer to have the optional security system

feature activated in the electronic control unit (ECU).

TASK 2: Lock the System the First Time

1. Start the engine and lock the parking brake.

2. Press and hold the MODE and SEL buttons for 3

seconds, then release. SECURE OFF should be

displayed. If not, repeat this step.

3. Wait until ENTER CODE displays, then press

and release SEL to advance the digit. When “0”

is displayed, press and release MODE to accept

the digit. TIP: If the ENTER CODE screen exits

due to inactivity, repeat step 2.

4. Press and release SEL to advance the second

digit. When “0” is displayed, press and release

MODE to accept the digit.

5. Press and release SEL to advance the third digit.

When “0” is displayed, press and release MODE

to accept the digit.

6. After accepting the third digit, view the display

screen. SECURE ON displays if the system locks.

NOTE: The system is now locked.

7. You must now unlock the system. Proceed imme-

diately to TASK 3.

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FEATURES

Instrument Cluster (MFD)

Rider Information Center

Security System (Ignition Lock System)

First Time Use of Your Security System

TASK 3: Unlock the System

1. When the engine is running, the display will

alternate between SECURE ON and

ENTER CODE. Wait until ENTER CODE

displays, then press and release SEL to

advance the digit. When “0” is displayed,

press and release MODE to accept the

digit.

2. Press and release SEL to advance the second

digit. When “0” is displayed, press and release

MODE to accept the digit.

3. Press and release SEL to advance the third digit.

When “0” is displayed, press and release MODE

to accept the digit.

4. After accepting the third digit, view the display

screen. SECURE OFF displays if the system

unlocks.

NOTE: The system is now unlocked.

5. You must now enter a new security code. Proceed immediately to TASK 4.

TASK 4: Enter Your New Security Code

1. Immediately after locking and unlocking the system, and while SECURE

OFF is displayed, press and release the MODE button to bring up the

ENTER CODE screen.

2. When ENTER CODE displays, use the SEL and MODE buttons to select

and accept each digit of a new personal security code.

3. After accepting the third digit, view the display

screen. The new code and CODE SET will dis-

888

play if the system accepted your new code. You

will not see this display again.

NOTE: Your new code is now set. The system is

NOT locked.

4. Record your new security code in a safe place for future reference.

Record your new personal security code here: __________________

TIP:If you lose your personal security code, see your dealer to have the code

reset to “000”. Then perform TASK 2 through TASK 4 to change the code

to one of your own choosing.

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FEATURES

Instrument Cluster (MFD)

Rider Information Center

Security System (Ignition Lock System)

Locking the System With Your Personal Security Code

1. Start the engine and lock the parking brake.

2. Press and hold the MODE and SEL buttons

for 3 seconds, then release. SECURE OFF

should be displayed. If not, repeat this step.

3. Wait until ENTER CODE displays, then

press and release SEL to advance the digit.

When the first digit of your security code is

displayed, press and release MODE to

accept the digit.

TIP:If the ENTER CODE screen exits due to inactivity,

repeat step 2.

4. Continue to use SEL and MODE to select

and accept the remaining two digits of the

code.

5. After accepting the third digit, view the

display screen. SECURE ON displays if the

system locks. Engine speed is now limited

and the snowmobile cannot be driven.

TIP:When the engine is running, the display will

alternate between SECURE ON and ENTER CODE.

6. If BAD CODE displays, the screen will then

return to the ENTER CODE screen. Repeat

steps 3-5 to re-enter the security code.

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FEATURES

Instrument Cluster (MFD)

Rider Information Center

Security System (Ignition Lock System)

Unlocking the System With Your Personal Security Code

1. When the engine is running, the display

will alternate between SECURE ON and

ENTER CODE. Wait until ENTER

CODE displays, then press and release

SEL to advance the digit. When the first

digit of your security code is displayed,

press and release MODE to accept the digit.

TIP:When the system is locked and engine temperature is above 120° F (49°

C), the correct password must be entered within 60 seconds or the engine

will shut down.

2. Continue to use SEL and MODE to select

and accept the remaining two digits of the

code.

3. After accepting the third digit, view the

display screen. SECURE OFF displays if

the system unlocks.

4. Re-enter your code if BAD CODE

displays.

NOTE: The system is now unlocked.

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FEATURES

Instrument Cluster (MFD)

Rider Information Center

Security System (Ignition Lock System)

Changing to a New Security Code

Any time you wish to change your current security code to a new code,

perform TASK 2 through TASK 4 of the First Time Use of Your

Security System procedure beginning on page 38. Instead of using the

factory default code “000” in TASK 2 and TASK 3, use your current

security code.

Security System Access Quick Reference

Now that you have become familiar with the procedure for locking and

unlocking the system, use the chart below as a quick reference.

Security System Access Quick Reference Chart

Action

Result

Start engine + Lock

parking brake + Press

and hold both MODE +

SELECT (SEL)

Displays ENTER CODE (to lock the system)

Press SELECT (SEL)

Press MODE

Advances a digit on the ENTER CODE screen

Accepts a digit and displays the next digit position (if

any remain) on the ENTER CODE screen

Opens ENTER CODE screen if MODE is pressed

immediately after locking and unlocking the system

(to change your security code)

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FEATURES

Instrument Cluster (MFD)

Rider Information Center

Diagnostic Display Mode

The diagnostic display mode is for informational purposes only. Please

see your POLARIS dealer for all major repairs.

The diagnostic mode is accessible only when the check engine warning

indicator is illuminated and a diagnostic code is active.

Do not stop the engine if you want to view the active code (failure

code). Active codes cannot be retrieved if power is interrupted to the

instrument cluster. The codes will become inactive codes if power is

interrupted. Inactive codes are stored in the history of the unit. Please

see your POLARIS dealer to retrieve inactive codes.

Use the following procedure to view active codes.

1. Do not stop the engine.

2. With the brake engaged, press and release the SELECT button or

SET switch to toggle to the diagnostic display mode. When a code

is active, the diagnostic display mode will appear immediately

following the engine hour display.

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

will begin to flash.

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

• The 2-6 digit suspect parameter number (SPN) in the information display

area indicates which component is generating the fault code.

• The 1-2 digit failure mode indicator (FMI) number in the odometer area

indicates the fault mode, such as open or short circuit.

4. More than one fault may be active. Press and hold the MODE

button or MODE switch for two seconds to toggle to the next active

code. Repeat until all codes are retrieved.

5. See page 57 for code definitions and failure descriptions.

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FEATURES

Instrument Cluster (Digital/Analog and MFD)

Rider Information Center

Diagnostic Display Code Definitions

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

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

Short-to-Ground: The wire is shorted to ground between the electronic

control unit and the item listed in the chart.

Shorted Load: The wires leading to the item listed in the chart are

shorted together, or the item has shorted internally.

Short-to-Battery: The wire leading from the item listed in the chart to

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

Diagnostic Codes

Component

Condition

Voltage Too High

SPN

FMI

Throttle Position Sensor

Voltage Too Low

Abnormal Rate of Change

Data Erratic, Intermittent or Missing

Voltage Too High

Vehicle Speed Sensor

Intake Air Temperature Sensor

105

Voltage Too Low

Barometric Pressure Sensor

Engine Temperature Sensor

Voltage Too High

108

110

Voltage Too Low

Voltage Too High

Voltage Too Low

Temperature Too High

Engine Overheat Shutdown

Temperature Above Normal Range

Voltage Too High

Alternator Power Supply

167

173

Potential (DC Chassis Voltage)

Voltage Too Low

Exhaust Temperature Sensor

Voltage Too High

Voltage Too Low

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FEATURES

Instrument Cluster (Digital/Analog and MFD)

Rider Information Center

Diagnostic Display Code Definitions

Diagnostic Codes

Component

ECU Memory

Condition

SPN

628

651

FMI

Checksum/CRC Error

Injector 1 (MAG) (Port Injector)

Injector 2 (PTO) (Port Injector)

Knock Sensor 1

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Voltage Too Low

652

731

Ignition Coil Primary Driver 1 (MAG) Driver Circuit Open/Grounded

1268

1347

1352

Fuel Pump Driver Circuit

Driver Circuit Open/Grounded

Knock Level Cylinder 1 (MAG)

Maximum Detonation

Correction Limit Reached

Knock Above Critical Level

Knock Level Cylinder 2 (PTO)

Maximum Detonation

Correction Limit Reached

1353

Knock Above Critical Level

Voltage Too Low

Sensor Supply Voltage 1 (TPS/

TMAP Sensor Power)

3509

3510

3598

Sensor Supply Voltage 2 (Ground

Speed Sensor)

Voltage Too Low

ECU Output Supply Voltage 2

(Injection Supply PWR)

Voltage Too High

Voltage Too Low

Throttle Release Signal

Voltage Too High

520194

Voltage Too Low

Throttle Stuck

Chassis Relay

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Driver Circuit Short to B+

Voltage Too High

520208

520215

524007

Exhaust Valve Solenoid

Fuel Type Selected

Voltage Too Low

Signal Out Of Range

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THE PERFECT FIT

Front Suspension Adjustments

Independent Front Suspension (IFS)

Factory settings, combined with user adjustments to the rear shock

spring, should be all that’s necessary to provide the best riding

experience for most riders. If all rear shock spring adjustments have

been exhausted and rider weight is at the very high or very low weight

range for the stock spring, additional adjustments are possible to the

IFS.

Settings will vary from rider to rider, depending on rider weight, vehicle

speed, riding style, and trail conditions. We recommend starting with

factory settings and then customizing each adjustment individually to

suit rider preference. The snowmobile should be methodically tested,

one change at a time, under the same conditions (trail and snow

conditions, vehicle speed, riding position, etc.) after each adjustment

until the best ride is achieved.

Break in the suspension for about 150 miles (240 km) before making

adjustments to the front suspension.

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. A-arms

IFS Adjustment Options

• Front shock spring preload

• Optional springs

• Optional shock valving

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THE PERFECT FIT

Front Suspension Adjustments

IFS Shock Spring Preload

Increasing spring preload will increase ski-to-ground pressure.

Decreasing spring preload will decrease ski-to-ground pressure. When

adjusting, be sure the springs on both the left and right sides of the

machine are at the same adjustment.

To change shock spring preload, grasp the

spring retainer and rotate it.

Initial IFS Preload Setting

Measure

(from body end to spring)

FOX shocks

4.25" (10.8 cm)

5.25" (13.3 cm)

Ryde FX shocks

Increasing the spring preload too much may

adversely affect the handling of the

snowmobile and the performance of the

suspension. Never exceed one inch (2.54

cm) of preload beyond the factory settings.

NOTICE: When decreasing preload, make sure

at least two turns of preload are holding

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.

Low

Preload

High

Preload

TIP:Other spring options are available. Please

see your POLARIS dealer.

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.

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 caution when handling high-pressure service equipment. We

recommend that this work be performed by a POLARIS dealer.

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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

suspension 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

bottom out harshly on a snowcross course.

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.

Suspension Performance Tips

• Rider weight usually determines the position at which the spring

preload 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.

Tip: Keep the suspension pivot points lubricated. This will reduce moisture and

rust build-up and ensure proper function of the suspension components.

Grease rear suspension pivots before adjusting the rear suspension. Refer

to the Pre-Ride Suspension Inspection on page 72.

Track Tension

Track adjustment is critical for proper handling. Always maintain

correct tension and alignment. Refer to the track tension maintenance

section beginning on page 112.

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THE PERFECT FIT

Rear Suspension Adjustments

Initial Spring Preload Setting (Sag Method)

To set up the rear suspension torsion

spring preload, measure the distance

between the ground and rear bumper. This

is measurement X.

Take the first measurement with no rider

and with the rear suspension at full

extension.

Tip: The rear bumper may need to be lifted

upward slightly to fully extend the rear

suspension.

Next, have the rider drop down hard on

the seat and bounce up and down several

times, collapsing the rear suspension.

With the rider seated, measure the

distance between the ground and the rear

bumper at the exact location used for

measurement X. This is measurement Y.

To determine sag, commonly referred to

as ride-in, subtract measurement Y from

X (sag=X-Y). If the measured sag is

incorrect, adjust the FRA position and/or

rear torsion spring preload.

See

Page

Suspension Recommended Sag Adjustment

INDY (121)

3-4 inches (7.5-10 cm) Torsion Spring

Preload

Tip: This is only an initial setup, and final spring preload may vary based on rider

preference and riding conditions. Accessory springs with a higher load

rating are available for some models. Please see your dealer for availability.

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THE PERFECT FIT

Rear Suspension Adjustments

Torsion Spring Preload

To adjust rear torsion spring preload, rotate the three-position cam using

the engine spark plug tool. 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.

Soft

Medium

Firm

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

Upper

Nuts

front limiter straps. Tighten the

straps to increase ski pressure.

Loosen the straps to reduce ski

pressure.

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.

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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

suspension 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.

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THE PERFECT FIT

Rear Suspension Adjustments

Suspension Coupling

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

independent movement between the rear torque and the front torque

arm.

Adjusting the RRSS either allows more weight to 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:

• Reduced weight transfer

• Improved chatter bump ride

• Improved cornering performance

• Increased load carrying capacity (2-up)

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THE PERFECT FIT

Rear Suspension Adjustments

Weight Transfer During Acceleration

The preferred method for controlling

weight transfer during acceleration is

by adjusting the rear rear scissor stop

(RRSS). The factory setting is the

best for most trail riding conditions.

HIGH

LOW

MEDIUM

To decrease weight transfer under

acceleration (for improved corner-

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 initial

setup and additional setup

instructions to help you achieve your

optimum ride. A scissor stop tool is

also available from your dealer.

RRSS

FRSS

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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 117.

If your snowmobile has carbide skags, it may be necessary to add track

studs to maintain proper vehicle control. Maintain a proper balance

between the number of studs and the length of carbide on the skags (the

more studs you use, the longer the carbide on the skags should be). See

your dealer's track studding chart.

Inspect skags frequently. Worn skags may reduce steering and braking

control on hard-packed snow and ice. Replace worn skags to maintain

proper balance and vehicle control.

WARNING! Loss of control can result in serious personal injury or death.

Proper balance of traction products on the skis and track must be maintained to

obtain proper vehicle control on hard-packed snow or ice. See your dealer for

assistance.

Wear Strips

To avoid excessive tunnel wear, tunnel wear strips must be installed

whenever track studding is used.

Install the appropriate wear strip kit. See your dealer.

Wear strips are designed for a specific stud length. See your dealer's

studding chart for recommended traction accessories.

NOTICE: Whenever wear strips are relocated, be sure there's adequate stud

clearance to the tunnel. Lack of clearance may result in damage to

tunnel.

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THE PERFECT FIT

Handlebar Component Fastener Torques

Shown with riser cover removed for clarity

3/4

Component

Torque

Do not over-tighten

IMPORTANT: Moving a handlebar component without first loosening its

screws/set screws may cut grooves into the handlebar, making it difficult

to secure the component. Do not move a handlebar component without

first loosening its mounting screws/set screws.

Take care to avoid damaging hand warmer/brake switch wires when

moving components.

1. Left Hand Control/Brake Master Cylinder

2. Upper / Lower Handlebar/Riser Clamps

3. Throttle Lever Block Set Screw

4. Throttle Lever Block Cover Screws

5. Auxiliary Engine Stop Switch Set Screw

6. Riser

24 in-lbs (2.7 Nm)

16 ft-lbs (21.6 Nm)

27 in-lbs (3 Nm)

6 in-lbs (0.7 Nm)

12 in-lbs (1.4 Nm)

Install with the “FWD”

stamp facing forward,

toward the hood.

Hand Guard Mounts (if applicable)

Hand-Tight

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THE PERFECT FIT

Left Hand Control Alignment

1. Loosen the four control block mounting screws.

CAUTION! Take care to avoid damaging hand warmer/brake switch wires

when moving components.

2. Move the control block to the

desired position.

Control Block

NOTE: If the control is loose and was

inadvertently moved without

loosening the screws, move the

control block slightly to the left or

right to relocate the pins.

3. Tighten the screws to specification

in the sequence shown in the image.

Do not over-torque.

Torque: 24 in-lbs (2.7 Nm)

Throttle Block Alignment

1. Slightly loosen the set screw on the

bottom of the housing.

2. Move the control block to the

desired position.

NOTICE: Take care to avoid damaging hand

warmer wires when moving

components.

Throttle Block

Set Screw

3. Tighten the screw to specification.

Do not over-torque.

Torque: 27 in-lbs (3 Nm)

4. With the engine off, test throttle lever movement after tightening the

screw. See page 86.

Engine Stop Switch Alignment

1. Slightly loosen the set screw on

the bottom of the housing.

2. Move the switch to the desired

position.

CAUTION! The stop switch must be

positioned in an easily accessible location.

Stop Switch

Set Screw

3. Tighten the screw to specification.

Do not over-torque.

Torque: 12 in-lbs (1.4 Nm)

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THE PERFECT FIT

Handlebar Adjustments

When adjusting handlebar position or angle, be sure the handlebar,

brake lever and throttle lever operate smoothly and do not hit the gas

tank, windshield or any other part of the machine when turned fully to

the left or right. If necessary, adjust the left and right hand controls. See

page 69.

Handlebar Position

1. Loosen the upper handlebar

clamp screws.

Handlebar

Clamp Screws

2. Adjust the handlebar forward or

rearward to the desired

position.

3. Tighten the screws to

specification. Maintain an

equal gap between the clamp

and riser while tightening. Do

not over-torque.

Torque: 16 ft-lbs (21.6 Nm)

Handlebar Angle

1. Loosen the lower riser clamp

screws.

2. Adjust the riser to the desired

position.

3. Tighten the screws to

specification. Maintain an

equal gap between the clamp

and riser while tightening. Do

not over-torque.

Riser Clamp

Screws

Torque: 16 ft-lbs (21.6 Nm)

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PRE-RIDE INSPECTIONS

Pre-Ride Checklist

Inspect all items on the checklist for proper operation or condition

before each use of the snowmobile. Procedures are outlined on the

referenced pages.

Item

See Page

Drive Belt Condition

Steering System

Recoil Rope

109

Coolant Level

101

Chaincase Oil Level

Injection Oil Level

Parking Brake Lock/Brake Lever/Brake System

Auxiliary Shut-Off Switch (Engine Stop Switch)

Ignition Switch

74, 75, 104

Headlight/Taillight/Brakelight

Suspension Mounting Bolts

Skags (Wear Bars)

117

Ski Saddle and Spindle Bolts

Hood and Side Panel Fasteners

Throttle Lever/Safety Switch

Rear Wheel Idler Bolts

85, 86

113

Tether Switch/Strap (if equipped)

Track Alignment/Condition

Rail Slide Condition

76, 114

117

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PRE-RIDE INSPECTIONS

Pre-Ride Suspension Inspection

Loose nuts and bolts can reduce your snowmobile's reliability and cause

needless repairs and down time. Before beginning any snowmobile trip,

a visual inspection will uncover potential problems. Check the

following items on a weekly basis or before any long trip.

Item

Check

Page

Suspension mounting bolts

Rear idler wheel bolts

Rear idler adjusting bolt locknuts

Torque arm bolts

Tightness

Condition

Tension

113

Carrier and bogie wheel bolts

Front torque arm limiter strap

Rail slide

117

112

117

Track

All rear suspension components

Ski runner/skag

Lubrication

Condition

Tightness

Ski spindle bolts

Tie rod end nuts

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PRE-RIDE INSPECTIONS

Before Starting the Engine

Before starting the engine, always refer to all safety warnings pertaining

to snowmobile operation. Never start the engine without checking all

vehicle components to be sure of proper operation.

WARNING! Operating the vehicle with worn, damaged, or malfunctioning

components could result in serious injury or death. Never start the engine

without checking all vehicle components to be sure of proper operation.

Read and Understand Your Owner's Manual

Read the Owner's Manual completely and refer to it often. The manual

is your guide to safe and enjoyable snowmobiling experience.

Throttle Lever

The throttle and brake are the primary controls of your snowmobile.

Always make sure both are functioning properly.

Squeeze the throttle lever to make sure it compresses evenly and

smoothly. When released, the lever should immediately return to the

idle position without binding or hesitation. If the throttle does not

function smoothly, or if you discover excessive lever freeplay, DO NOT

start the engine. Have the throttle serviced immediately.

Throttle Safety Switch

Test the throttle safety switch system before the snowmobile is operated.

See page 85.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

Brakes

Always check the following items for proper operation before starting

the engine.

Brake Lever Travel

Squeeze the brake lever. It

should move no closer to the

handgrip than 1/2 inch (1.3

1/2 in. (1.3 cm)

cm). A smaller distance indi-

cates low brake fluid level or

air in the hydraulic system.

Refer to the brake bleeding

information on page 106 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 105.

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.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

Parking Brake Lever Lock

Use the parking brake lever lock

only when you want the

snowmobile to remain stationary,

such as when parked on an

incline for a period of five

minutes or less.

1. Brake Lever

2. Parking Brake Lever Lock

3. Master Cylinder Reservoir/Cover

4. Fluid Level Indicator

Lock Engagement

To engage the lock, squeeze the brake lever tightly and push forward on

the lock. Hold the lock forward while releasing the brake lever.

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

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

The parking brake light on the gauge will light up if the parking brake

lever lock is set while the engine is running. It will also be lit when the

service brake is in use. If the parking brake light does not come on when

the parking brake or service brake is in use, have it serviced by your

dealer.

Lock Release

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

to the unlocked position.

WARNING! If the parking brake lever lock is partially or entirely engaged while

riding, the brakes may overheat, resulting in brake damage. In extreme cases it

could cause a fire, which could result in serious injury or death. Always ensure

that the lever lock is completely disengaged before operating the snowmobile.

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PRE-RIDE INSPECTIONS

Before Starting the Engine

Steering System

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

snowmobile, resulting in serious injury or death. Keep the underhood area free

of snow and ice.

Before driving, manually turn the skis to the left and right to be sure ice

and snow are not interfering with full left and right steering. If difficulty

is encountered, remove ice and snow build-up that may be obstructing

the steering linkage.

Track

Track damage or failure caused by operation on ice or poor lubrication

conditions voids the track warranty.

WARNING! Operating the snowmobile with a damaged track increases the

possibility of track failure, which could cause loss of control resulting in serious

injury or death. Always inspect the track for damage before using the vehicle.

WARNING! Use of traction products such as studs increases the possibility of

track damage and/or failure. Driving at high speeds for extended periods of time

in marginal lubrication could severely damage track rods, break track edges,

and cause other track damage. Examples of marginal lubrication would include

frozen bodies of water without snow cover, icy trails, and no-snow conditions.

Hood and Side Panel Fasteners

The hood and side panels of the snowmobile protect the operator from

moving parts. Never operate a snowmobile with the hood or side panels

open or removed. Always ensure that the hood and side panels are

securely in place before starting the engine.

Seat Latches

If your snowmobile is equipped with a removable seat, ensure that the

seat is properly installed and securely latched before each use of the

snowmobile.

Recoil Rope

Inspect the recoil rope and handle for excessive wear, and make sure the

knot securing the rope inside the handle is secure. If excessive wear is

found, see your POLARIS dealer for replacement.

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PRE-RIDE INSPECTIONS

Start the Engine and Check

Before starting the engine, always refer to all safety warnings pertaining

to snowmobile operation. Never engage the starter when the engine is

running. Never start the engine without checking all vehicle components

to be sure of proper operation. See Before Starting the Engine beginning

on page 73.

Engine Stop Switch

Check the auxiliary shut-off switch for proper operation. Push the

switch down to stop the engine. Pull it up to allow restarting.

Ignition Switch

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

Tether Switch (if equipped)

If your snowmobile has a tether switch, remove the tether from the

switch to make sure the engine stops immediately.

Lighting

Check the headlight (high and low beam), taillight, and brake light.

Replace burned out lamps before operating.

Mirrors (if equipped)

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

Operating Area

Before driving away, check your surroundings. Be aware of obstacles

and make sure bystanders are a safe distance from the snowmobile.

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OPERATION

Starting the Engine

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

engine damage, especially if the transmission is in reverse. Never

engage the starter when the engine is running.

1. Turn the key to the ON position.

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

3. If equipped with electric start, turn the key to START to crank the

engine. Release the key to the ON position when the engine starts.

4. If not equipped with electric start, grasp the starter handle and pull

slowly until the recoil engages; then pull abruptly to crank the

engine.

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

snap back into the housing. Damage may result.

5. If the engine does not start after several attempts, slightly depress

the throttle no more than 1/4 inch (2.54 cm) open while cranking the

engine. When the engine starts, immediately release the throttle.

CAUTION! To avoid injury and/or engine damage, do not operate the electric

starter or pull-rope starter while the engine is running.

NOTICE: Operating the vehicle immediately after cold starting could cause

engine damage. Allow the engine to warm up for several minutes

before operating the vehicle. If cold drive-away is attempted, the

engine RPM may stumble slightly to protect the engine.

Restarting an Engine

If the rider stops the engine by pushing the engine stop switch down,

restart the engine using the normal starting procedure. If the engine fails

to start using the normal procedure:

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

2. Turn the key to the OFF position.

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

open position.

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

5. Release the throttle.

6. Restart the engine using the normal starting procedure.

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OPERATION

Break-In Period

Engine Break-In

Always follow these recommended break-in procedures for new or

rebuilt engines. The first tank of fuel is considered the break-in period

for the engine.

Premix the first tank of fuel and fill the oil reservoir as outlined below.

Oil added to the fuel and oil injection systems will provide the necessary

engine lubrication.

Oil Recommendations

First Tank of Fuel:

After Break-in:

POLARIS VES 2-Cycle Oil

VES RACE 2-Cycle Oil

Extreme Arctic Conditions, sustained

temperature is at or below -40° F (-40° C)

See page 126 for the part numbers of POLARIS products.

Never mix brands of oil. Serious chemical reactions can cause injection

system blockage, resulting in serious engine damage. Oils may also be

incompatible and the result could be sludge formation, filter blockage,

and reduced cold weather flow rates. All POLARIS oils are compatible

with each other.

Initial Fuel Premix

Always premix fuel in 5-gallon (19-liter) increments in a separate fuel

container. Never add oil directly to the fuel tank.

Fuel

VES 2-Cycle Oil

Ratio

Each 5 gal. (19 l)

16 oz. (473 ml)

40:1

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OPERATION

Break-In Period

Engine Break-In

Excessive heat build-up during the first three hours of operation will

damage close-fitted engine parts. Do not operate at full throttle or high

speeds for extended periods during the first three hours of use. Vary the

throttle openings and vehicle speeds to reduce friction on all close-

fitting machined parts, allowing them to break in slowly without

damage.

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

may cause serious engine damage. We recommend the use of

POLARIS lubricants for your vehicle.

Drive with extra caution during the break-in period. Perform regular

checks on fluid levels, lines, and all other important areas of the

snowmobile.

Oil Injection System

Always check and fill the oil bottle when refueling. See page 84.

NOTICE: Serious engine damage can occur without the proper lubrication.

Check the oil bottle level often during the first tank of fuel. If the oil

level doesn't go down, contact your dealer immediately.

Drive Belt Break-In

The break-in period for a new drive belt is 30 miles (48 km). During this

time, vary the throttle position under 50% and limit full throttle use.

Always take time to warm up the belt and driveline prior to operating

the snowmobile. Free the track and skis from the ground before

engaging throttle.

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OPERATION

Track Warm-Up

WARNING! A loose track or flying debris could cause serious injury or death.

Stand clear of the front of the snowmobile and the moving track. Never hold the

snowmobile up or stand behind it while warming up the track. Do not use

excessive throttle during warm-up or when the track is free-hanging. Use a

stable rear support.

WARNING! Use of traction products such as studs, ice growsers, etc. will

increase the possibility of track damage and/or failure. This could cause loss of

control, resulting in serious injury or death. Always inspect for track damage

before operating the snowmobile.

Follow these steps to ensure proper warm-up of the engine, drive train

and track.

1. Use an appropriate stand to securely support the rear of the

snowmobile at the rear bumper. The track should be about 4 inches

(10 cm) off the ground.

2. Start the engine and allow it to warm up two to three minutes.

3. Depress the throttle abruptly and allow the track to rotate several

revolutions.

TIP:It will take longer to warm up the track sufficiently during colder outdoor

temperatures.

4. Release the throttle, apply the brakes, shut off the engine and lower

the snowmobile to the ground.

5. Grasp the skis by their front loops and move them from side to side

to loosen snow and ice.

Slide Rail and Track Cooling

NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide

rail and track, resulting in premature wear and failure. Reduce speeds

and frequently drive into fresh snow to allow adequate cooling and

polishing of the slide rail and track surfaces. Avoid operating on ice,

hard-packed surfaces or roads.

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OPERATION

Fuel

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

• Always turn off the engine before refueling.

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

• Do not smoke or allow open flames or sparks in or near the area where

refueling is performed or where gasoline is stored.

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

and water and change clothing.

• Never start the engine or let it run in an enclosed area. Engine exhaust fumes

are poisonous and can cause loss of consciousness or death in a short time.

WARNING

The engine exhaust from this product contains chemicals known to cause

cancer, birth defects or other reproductive harm. Operate this vehicle only

outdoors or in well-ventilated areas.

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OPERATION

Fuel Recommendation

For peak performance, POLARIS recommends the use of 91 octane fuel

or higher, with no ethanol. Although 87 octane fuel is usable, some

engine performance will be lost and fuel economy will decrease. Do not

use lower than 87 octane fuel. Do not use fuel containing more than

10% ethanol. Never use E85 fuel in your snowmobile.

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

damage. Perform maintenance as recommended.

Prolonged exposure to petroleum based products may damage paint.

Always protect painted surfaces when handling fuel.

Fuel System Deicers

If you use non-ethanol fuel (sometimes labeled “non-oxygenated”),

POLARIS recommends the regular use of isopropyl-based fuel system

deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline

to prevent damage resulting from fuel system icing. Never use deicers

or additives containing methanol. POLARIS recommends the use of

Carbon Clean. See page 126 for the part numbers of POLARIS

products.

If you use fuel with up to 10% ethanol (sometimes labeled

“oxygenated”) do not add deicers or additives that contain any form of

alcohol.

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OPERATION

Oil

Low Oil Level

Always maintain the oil level between

the “add” mark and the bottle neck.

Do not fill the bottle neck. See page

79 for oil recommendations.

“Add”

Mark

1. Immediately stop the engine if the

low oil indicator light comes on.

2. Open the left side panel.

3. View the oil level in the oil bottle.

4. Add oil as needed before operating.

NOTICE: Operating the snowmobile without adequate engine lubrication can

result in serious engine damage. Always check the oil level when

refueling. Add oil as needed.

The oil bottle cap is vented to allow proper oil flow. See your POLARIS

dealer for recommended replacement parts.

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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.

Stop

Switch

Throttle Safety Switch

The throttle safety switch is designed to stop the engine whenever all

pressure is removed from the throttle lever and the throttle cable or

valves do not return to the normal closed position.

WARNING! Operating the snowmobile with a faulty throttle safety switch can

result in serious injury or death in the event of an accident. If the throttle safety

switch does not shut off the engine during a carburetor/throttle system

malfunction, immediately push down the engine stop switch. Do 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 pressure on

the pivot pin in the direction shown

in the illustration.

4. Apply a slight amount of throttle. A properly functioning switch

must shut down the engine.

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OPERATION

Throttle Lever

WARNING! An improperly functioning throttle lever may cause erratic

snowmobile behavior and loss of control, which could result in serious injury or

death. If the throttle lever does not work properly, DO NOT start the engine.

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

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor/throttle body to

determine what caused the safety switch to activate.

3. Test the throttle lever by compressing and releasing it several times.

The lever and cable must return to the idle position quickly and

completely.

4. If the throttle lever operates properly, turn the ignition switch on and

go through normal starting procedures.

5. If the engine doesn't start, take the snowmobile to an authorized

POLARIS dealer for service.

Excessive freeplay in the throttle cable may cause the safety switch to

activate, preventing the engine from starting. If this occurs, return the

snowmobile to an authorized POLARIS dealer for service.

If an emergency exists and it's necessary to start the engine, the throttle

safety switch and engine stop switch may be disconnected from the wire

harness. When these switches are disconnected, the ignition key switch

must be used to shut off the engine. DO NOT continue to operate the

snowmobile with the throttle safety switch disconnected. Return the

snowmobile to an authorized POLARIS dealer for service as soon as

possible.

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OPERATION

Electronic Reverse (PERC)

WARNING

Improper reverse operation, even at low speeds, may cause loss of control,

resulting in serious injury or death. Damage will occur to the chaincase or

transmission if shifting is attempted when the engine is operating above idle

speed.

• Shift to or from reverse only when the snowmobile is stopped and when

engine speed is at idle.

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

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

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

engine damage, especially if the transmission is in reverse. Never

engage the starter when the engine is running.

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

3. Push the yellow reverse button on the left-hand control for one

second, then release. The engine will automatically reduce RPM

and start a reverse rotation. A flashing reverse light on the

instrument panel will indicate that the transmission is in reverse.

4. Apply the throttle slowly to make sure the transmission is in

reverse.The maximum engine RPM will be 6000 when in reverse.

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

restarted.

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OPERATION

Electronic Reverse (PERC)

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

engine damage, especially if the transmission is in reverse. Never

engage the starter when the engine is running.

2. Push the yellow reverse button for one second and release. The

engine will slow and begin to rotate forward. The light on the

instrument panel will shut off.

3. Apply the throttle slowly to make sure the transmission is in

forward.

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the

event of an emergency. See page 85 for more information about the

engine stop switch and throttle safety switch.

SYSTEM

Ignition Switch

WHAT IT DOES

Interrupts ignition circuit

Brake

Slows jackshaft

Engine Stop Switch

Throttle Safety Switch

Tether Switch (Option)

Interrupts ignition circuit

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OPERATION

Daily Storage

At the end of each ride, park the snowmobile on a level surface and

support it at the rear with an appropriate track stand. The track should be

suspended approximately 4 inches (10 cm) off the ground.

Remove the key and cover the snowmobile.

Towing

For your safety, do not attempt to use a tow hitch until you've read the

following warnings and understand the proper hitch functions.

WARNING! Objects towed with a rope have no braking power and can easily

collide with the rear of the snowmobile or other objects, resulting in serious

injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle

with a rope. Only a stiff metal pole connecting the towed object and the tow hitch

on the snowmobile should be used. If passengers are to be towed on a

toboggan or sled, make sure the pole is at least four feet (1.2 meters) long to

prevent any possibility of contact between the snowmobile's track and a person

riding in the towed object.

WARNING! Braking distances increase when towing loads. Slow down to

maintain control of the snowmobile.

If the snowmobile becomes inoperable and must be towed, and if it isn't

possible to use a rigid tow bar, attach the tow rope to the ski spindles

(not to the ski loops) to prevent damage to the steering components.

Remove the drive belt before towing, and have someone ride on the

towed snowmobile to operate the brake and steering when necessary.

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

serious damage to the engine and drive system. Always remove the

drive belt from a disabled snowmobile before towing.

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MAINTENANCE

Emission Control Information

Any qualified repair shop or qualified person may maintain, replace, or

repair the emission control devices or systems on your snowmobile.

Emission Control Label

Your snowmobile is equipped at the time of sale with an emission

control information (ECI) label and a factory-installed emissions

information hangtag. These items are required by U.S. Environmental

Protection Agency regulations. The ECI label is permanently affixed to

either the right side of the tunnel or the engine recoil cover. The ECI

label should not be removed, even after you purchase the snowmobile.

You may remove the factory-installed emissions information hangtag,

which is intended solely for your use in making a purchasing decision.

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum

octane level of 87 (R+M)/2. If your snowmobile is 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

available to your qualified service technician. Reverse (if equipped)

must not be engaged during engine tune-ups.

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty, and

read the maintenance section of your owner's manual. You are

responsible for ensuring that the specified maintenance is performed.

POLARIS recommends that you contact an authorized POLARIS dealer

to perform any service that may be necessary.

Non-ionizing Radiation

This vehicle emits some electromagnetic energy. People with active or

non-active implantable medical devices (such as heart monitoring or

controlling devices) should review the limitations of their device and the

applicable electromagnetic standards and directives that apply to this

vehicle.

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MAINTENANCE

POLARIS Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow

recommended regular maintenance and perform service checks as

outlined in this manual. Record maintenance and service in the

Maintenance Log beginning on page 140.

The recommended maintenance schedule on your snowmobile calls for

service and maintenance inspections at 150 miles (240 km), 500 miles

(800 km) and 1000 miles (1600 km). These inspections should be

performed by a qualified service technician. For continued optimum

performance and component life, continue maintenance checks at 1000

mile (1600 km) intervals.

All necessary replacement parts and labor incurred, with the exception

of authorized warranty repairs, become the responsibility of the

registered owner. If, during the course of the warranty period, part

failures occur as a result of owner neglect in performing recommended

regular maintenance, the cost of repairs are the responsibility of the

owner.

Personal safety is critical when attempting to service or make

adjustments to your snowmobile. If you're not familiar with safe service

or adjustment procedures and the use of tools, or if you don't feel

comfortable performing these tasks yourself, contact an authorized

POLARIS dealer for service.

NOTICE: Hot components can cause damage to plastic. Always make sure the

exhaust system and engine have cooled before tipping the

snowmobile on its side for service or inspection.

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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

Page

Frequency

150 mi.

500 mi.

1000 mi.

2000 mi.

Pre-

(240 km) (800 km) (1600 km) (3200 km)

Season

CLUTCH

Clutch Alignment Offset

(without belt)

108

Drive Belt Condition

Clutches

109

108

Belt Tension

Clutch Sheaves

108

ENGINE/COOLING

Engine Mounts

Recoil Rope

Cylinder Head Bolts

Cylinder Base Nuts

Ignition Timing BTDC

VES System

Coolant Level

101

Coolant Change

Coolant Hose

R - Every 5 years

Coolant Circulation

Coolant Leaks

Spark Plugs

103

Exhaust Pipe

Exhaust Retaining

Springs

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)

C - Clean

R - Replace

L - Lubricate

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MAINTENANCE

Periodic Maintenance Interval Table

Item

See

Page

Frequency

150 mi.

500 mi.

1000 mi.

2000 mi.

Pre-

(240 km) (800 km) (1600 km) (3200 km)

Season

BRAKES

Hose Routing

Hose Condition

Fluid Leaks

Brake Pads

104

Brake Disc

Parking Brakes

Brake System

74,

104

Brake Fluid

105

FUEL MANAGEMENT

Idle RPM

Throttle Lever

Oil Pump Lever

(synchronize)

Throttle Position Sensor

Fuel / Vent Hoses

Fuel Filter

100

R - Every 2000 mi. (3200 km) or Every 2 years

Oil Filter

Oil Lines

Air Box

ELECTRICAL

Auxiliary Shut-Off

Switch

Throttle Safety Switch

Ignition Switch

Taillight

Brakelight

Headlight

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MAINTENANCE

Periodic Maintenance Interval Table

Item

See

Page

Frequency

150 mi.

500 mi.

1000 mi.

2000 mi.

Pre-

(240 km) (800 km) (1600 km) (3200 km)

Season

CHASSIS

Ski Toe Alignment

Suspension Mounting

Bolts

Bolt Torques

See your dealer every 1000 mi. (1600 km) for inspection

Rear Suspension

Fasteners

Steering Fasteners

Suspension Shock Oil

(SP Models)

Cooling Fins and Shroud

Skags (Wear Bars)

117

Ski Saddle/Spindle Bolts

Drive Chain Tension

103

Hood and Side Panel

Fasteners

Rear Wheel Idler Bolts

Idler Bolt Jam Nut

Camber Alignment

Handlebar Centering

Tether Switch and Strap

Track Alignment

113

114

112

Track Tension

Front Limiter Strap

Rail Slide Condition

Chaincase Oil

117

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)

C - Clean

R - Replace

L - Lubricate

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MAINTENANCE

Hood and Side Panels

The hood and side panels

protect the operator from

moving parts. Never operate a

snowmobile with the side

panels open or removed.

Always ensure that the hood

and side panels are installed and

securely latched before starting

the engine.

Strap

To open a side panel, rotate the

two 1/4-turn fasteners at the

upper edges of the side panel.

Release the strap at the lower

edge of the side panel.

To remove a side panel, open

the side panel, then pull the

panel outward to release the

tabs at the lower edge of the

panel. Lift the side panel away

from the snowmobile.

1/4-Turn Fasteners

Removing the hood is not

recommended. Any service

requiring the removal of the

hood should be performed by an

authorized POLARIS dealer.

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MAINTENANCE

Lubrication

Rear Suspension

Lubricate the suspension pivot shafts with POLARIS All Season Grease

at the intervals outlined in the Periodic Maintenance Table beginning on

page 92 and before seasonal storage. When operating in heavy, wet

snow conditions, lubricate every 500 miles (800 km).

Lack of lubrication will adversely affect your ride and the life of the

suspension. For more information about suspension lubrication and

adjustments, see your POLARIS dealer.

INDY Rear Suspension (121)

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MAINTENANCE

Lubrication

Chaincase Oil

Check and change the chaincase oil at the intervals outlined in the

maintenance charts beginning on page 91. Maintain the oil level at the

top of the fill plug hole. POLARIS recommends the use of POLARIS

Synthetic Chaincase Lube. See page 126 for the part numbers of

POLARIS products.

Oil Level

Fill Plug

1. Position the vehicle on a level

surface.

2. Remove the fill plug.

3. Using a funnel, slowly add the

recommended oil until the fluid

begins to overflow.

4. Wipe the fill area with a clean

cloth.

5. Reinstall the fill plug.

Torque: 6-10 ft-lbs (8-13 Nm)

Oil Change

1. Position the vehicle on a level surface.

2. Place a drain pan under the drain plug. Remove the drain plug.

Allow the oil to drain completely.

3. Clean off all metal shavings from the plug.

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

free of burrs, nicks or scratches.

4. Reinstall the drain plug.

Torque: 6-10 ft-lbs (8-13 Nm)

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

6. Using a funnel, slowly add the recommended oil until the fluid

begins to overflow. Fluid capacity is 9 oz. (266 ml).

7. Wipe the fill area with a clean cloth.

8. Reinstall the fill plug.

Torque: 6-10 ft-lbs (8-13 Nm)

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MAINTENANCE

Spark Plugs

Spark Plug Recommendations

A new engine can cause temporary spark plug fouling due to the

preservative added during the assembly process. Avoid prolonged idle

speeds, which cause plug fouling and carbonization.

Refer to the specifications section for the specific spark plug to be used

in your snowmobile.

Change the spark plugs at the intervals outlined in the Periodic

Maintenance Table beginning on page 91.

• Use recommended spark plugs with the proper gap.

• Use only resistor-type spark plugs.

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

• Always carry spare spark plugs.

NOTICE: Using non-recommended spark plugs can result in 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.

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Spark Plugs

Spark Plug Inspection

Spark plug condition is indicative of engine operation. The spark plug

firing end condition should be read after the engine has been warmed up

and the vehicle has been driven at higher speeds. Immediately check the

spark plug for correct color.

CAUTION! A hot exhaust system and engine can cause burns. Wear

protective gloves when removing a spark plug for inspection.

1. Remove the left side panel.

2. Remove the spark plug cap.

3. Using the special wrench provided in the tool pouch, rotate the

spark plug counter-clockwise to remove.

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

specification.

5. Reinstall the spark plug cap.

Spark Plug Condition

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few

combustion deposits. The electrodes are not burned or eroded. This

indicates the proper type and heat range for the engine and the service.

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

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

body adjustments.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil or

use of non-recommended injection oil.

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MAINTENANCE

Intake Filters

The intake filters on the left

and right console limit snow

ingestion into the intake

Intake

Filter

system. When operating in

loose powder snow, check the

filters periodically to remove

any accumulation of snow.

Fuel Pump

All fuel pump service must be performed by an authorized POLARIS

dealer. Do not attempt to service the fuel pump.

Fuel Filter/Fuel Lines

See your POLARIS dealer for replacement of the fuel filter at the

intervals outlined in the Periodic Maintenance Table beginning on page

92.

Contaminated or poor quality fuel will shorten the life of the fuel filter

and result in poor engine performance. Always store fuel in clean fuel

containers. If low fuel pressure or reduced engine performance occurs

between the recommended fuel filter service intervals, the filter may

need replacement. See your dealer.

Inspect the fuel lines regularly for signs of deterioration or damage.

Always check fuel line condition after periods of storage. Normal

deterioration from weather and fuel compounds may occur. Replace

worn or damaged fuel lines promptly.

NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel

lines may cause damage to the lines. If a fuel line has been damaged

or kinked, replace it promptly.

Oil Lines/Oil Filter

Inspect oil line condition every 1000 miles (1600 km) as outlined in the

maintenance charts beginning on page 91. See your dealer for

replacement of the in-line oil filter every 2000 miles (3200 km).

100

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Cooling System

Coolant

POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix.

This antifreeze is already premixed and ready to use. Do not dilute with

water. See page 126 for the part numbers of POLARIS products.

To ensure that the coolant maintains its ability to protect the engine, we

recommend that the system be completely drained every five (5) years

and fresh Antifreeze 50/50 Premix added.

Any time the cooling system has been drained for maintenance or repair,

replace the coolant with fresh Antifreeze 50/50 Premix.

Coolant Level

The engine coolant level is controlled by the recovery system. The

recovery system components are:

• Coolant bottle/overflow tank

• Pressure cap

• Connecting hoses

Always maintain the coolant level at or

slightly above the FULL COLD mark on

the coolant bottle (when the engine is

cold).

“Full Cold” Mark

1. Stop the engine.

2. Open the right side panel.

3. View the coolant level in the coolant

bottle.

4. Add coolant as needed.

NOTICE: Operating the snowmobile with insufficient coolant will result in

overheating and serious engine damage. Always maintain the coolant

level as recommended.

101

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Cooling System

Bleeding the Cooling System

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

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

Use of a non-standard pressure cap will not allow the recovery system to

function properly. If the pressure cap needs replacement, contact your

dealer for the correct part.

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

engine damage may result.

1. Position the vehicle so that the top of the tunnel is level. Elevate the

front of the vehicle slightly if necessary.

2. Make sure the engine is cold before continuing.

3. Remove the right side panel.

4. Fill the coolant bottle with properly mixed coolant to the maximum

mark. Do not install the pressure cap at this time.

5. Remove the bleed screw from the water outlet manifold and/or the

thermostat housing. Allow the coolant to bleed through the system

until it runs out the bleed holes. Reinstall the bleed screw into the

manifold.

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

7. Reinstall the side panel. Always ensure that the hood and side

panels are securely in place before starting the engine.

8. Start the engine and run at a fast idle for two to three minutes.

Loosen the bleed screw occasionally to purge any trapped air.

9. Stop the engine and check the coolant bottle level. Add coolant as

needed. Reinstall the side panel.

10. Carefully and briefly touch the top of the tunnel cooler under the

seat. If the system is bled properly, the cooler will be warm to the

touch. If not, repeat step 8. Lift the front of the snowmobile slightly

to assist in the bleeding.

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

panel.

12. Carefully lower the front end of the snowmobile.

102

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Exhaust System

Check the exhaust system for wear or damage at approximately 2000

miles (3200 km). Always allow the engine and exhaust system to cool

completely before inspecting.

CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for

the exhaust system to cool. Never perform this procedure with the engine

running.

1. Open the side panels and remove the hood. See page 95.

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

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

grommets.

4. Check for loose clamps on the pipe covers.

Drive Chain Tension

Check drive chain tension weekly and before each long trip.

1. Remove the side panels.

2. Rotate the driven clutch

counter-clockwise to move all

chain slack to the tensioner

side. Lock the brake lever

lock, or have an assistant hold

the brake lever firmly.

3. Loosen the adjuster bolt jam

nut.

4. Finger tighten the adjuster bolt

until it can no longer be

adjusted by hand, then back

Jam

Nut

Adjuster

Bolt

off 1/4 turn.

5. Tighten the jam nut while

holding the adjuster bolt.

Torque: 21 ft-lbs (28 Nm)

6. Reinstall the side panels.

7. Release the brake lever lock.

103

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Brakes

Hydraulic Brake Inspection

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

page 74.

Brake pads must be replaced when the brake pad material becomes

thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A

kit is available for replacing brake pads. See your dealer.

WARNING! Brake failure during operation can result in serious injury or death.

Properly functioning brakes are vital to your safety. Be sure the brake pads do

not drag on the disc and that brake lever travel is not excessive. Always replace

brake pads when the brake pad material becomes thinner than the backing plate

(approximately 1/16 inch or 1.5 mm).

Brake Components

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material (Replace

when thickness is less than

1/16 inch or 1.5 mm).

4. Anti-rattle springs (come

with brake pad kit)

Excessive Lever Travel

Hydraulic brakes are self-

adjusting, but if excessive brake

pad clearance develops, bring the

snowmobile to an authorized

POLARIS dealer for inspection

and adjustment.

104

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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 126 for the part numbers of POLARIS

products.

WARNING! After opening a bottle of brake fluid, always discard any unused

portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it

rapidly absorbs moisture from the air. The moisture causes the boiling

temperature of the brake fluid to drop, which can lead to early brake fade and

the possibility of accident or serious injury.

WARNING! Keep the master cylinder cover free of dirt and debris. The vent slits

allow for diaphragm movement, and if they become plugged, movement of

brake fluid below the diaphragm may be restricted, altering brake function.

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

up spills immediately.

105

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Brakes

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause spongy brake lever action.

Bleed the system before operating the snowmobile.

WARNING! Operating the vehicle with a spongy brake lever can result in loss of

brakes, which could cause an accident and lead to serious injury or death.

Never operate the vehicle with a spongy-feeling brake lever.

During the bleeding procedure, keep the brake handle as level as

possible. The reservoir must be in this position to minimize the

possibility of air entering the system through the reservoir vent.

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

2. Fill the master cylinder reservoir to between the MIN and MAX

marks or 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir

opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder

valve 3/4 of a turn to release air.

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

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a

solid stream free of air bubbles.

WARNING! Overfilling the master cylinder leaves no room for fluid expansion

and may cause the brakes to lock, resulting in serious injury or death. Always

add brake fluid to the fill line as recommended.

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

See page 105.

8. Reinstall the gasket and cover.

106

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Lights

When servicing a halogen lamp, avoid touching the lamp with bare

fingers. Oil from your skin leaves a residue, causing a hot spot that will

shorten the life of the lamp. If fingers do touch a lamp, clean it with

denatured alcohol.

Headlight Lamp Replacement

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

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

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

bulb.

4. Apply dielectric grease to the socket and install the new bulb.

Rotate the bulb 1/4 turn clockwise to secure it.

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

6. Secure the foam shield.

Taillight/Brake Light Replacement

The taillight assembly is not serviceable. If the light fails to operate

properly, replace the entire taillight assembly.

107

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Clutch System

Periodically inspect clutch sheaves for damage, wear or belt residue. To

maintain optimum performance, clean with non-oil based cleaners such

as isopropyl alcohol.

WARNING! If you become aware of higher than normal clutch engagement or

an unusual vibration or shift pattern, see your dealer immediately. Do not

operate the snowmobile until repairs have been made.

All clutch maintenance and repairs must be performed by an authorized

POLARIS dealer. Any unauthorized modifications to clutches, such as

adding or removing weights, will void the warranty.

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

made of a material that may be damaged if lubricated. Do not lubri-

cate clutch bushings.

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum

performance. See your dealer for service and adjustments. A special tool

is required to check for proper alignment.

108

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Clutch System

Drive Belt Condition

Periodically check the condition and tension of the drive belt. Inspect

the belt for signs of excessive wear: frayed edges, missing cogs, cracks

and excessive looseness. Replace the belt if any of these conditions

exist. See Drive Belt Troubleshooting on page 131.

Always carry a spare drive

belt. Store the spare belt in

the belt clip located under

the left side of the hood.

For improved drive-away during extremely cold temperatures, remove

the belt and warm it to room temperature. Reinstall it before starting the

snowmobile.

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 pres-

sure while measuring at point

2. This measurement should be

1 1/4 inches (3.2 cm).

Drive Belt Adjustment

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

2. Using a 1/8-inch Allen wrench, turn the set screw inward

(clockwise) to increase the distance between the sheaves or outward

(counter-clockwise) to decrease the distance.

3. Tighten the jam nut.

109

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Clutch System

Drive Belt Removal

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

snowmobile must be stopped after forward motion to prevent damage

to components during belt removal. Rotate the driven clutch counter-

clockwise 1/4 turn by hand to ensure forward engagement before

attempting to remove the belt.

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

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

Lock the parking brake.

2. Remove the left side panel.

3. Rotate the driven clutch counter-clockwise 1/4 turn by hand to

ensure forward engagement.

4. Locate the L-wrench in the tool kit. Install the wrench into the open

threaded hole in the outer sheave of the clutch.

5. Turn the wrench clockwise until the sheaves open far enough to

remove the belt. If the wrench does not turn readily, rotate the

driven clutch counter-clockwise an additional 1/4 turn by hand and

try again.

6. Remove the belt from the driven clutch.

Drive Belt Installation

1. With the L-wrench inserted into

the threaded hole and the sheaves

in the open position, install the

drive belt.

TIP:Install the belt so that the numbers can

be read correctly on the left side of the

vehicle, or in the direction in which the

belt was originally installed.

2. Wiggle the belt to remove slack

while removing the L-wrench.

3. Reinstall the side panel.

4. Break in the new belt. See page 80.

110

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MAINTENANCE

Track Maintenance

Track Inspection

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

snowmobile, which could cause serious injury or death. Never operate with a

damaged track. Never rotate a damaged track under power.

1. Using a hoist, safely lift and

support the rear of the

snowmobile off the ground.

2. Rotate the track by hand to

check for damage.

3. Carefully examine the track

along the entire length of each

rod. Bend the track to check

for breakage.

4. Replace the track if any rod

damage is found.

Rod

Track Lubrication

The slide rail needs snow for lubrication. Excessive wear indicates

insufficient lubrication. A new rail slide can cause faster heat build-up

in limited lubrication, resulting in excessive wear.

WARNING! Operating with insufficient lubrication between the rail slide and

track guide clips can cause track failure, loss of vehicle control and loss of

braking ability, which can result in serious injury or death. Avoid operating for

extended periods on ice and other surfaces that have little or no snow for

lubrication.

If excessive rail slide wear occurs due to poor snow conditions,

additional 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.

111

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MAINTENANCE

Track Maintenance

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

checks and adjustments recommended on the following pages, stay clear of all

moving parts. Never perform track measurement or adjustments with the engine

running.

Track Tension

Track adjustment is critical for proper handling. Always maintain

correct tension and alignment.

TRACK TENSION DATA CHART

Measurement

Location

Slack

Measurement

Suspension

Weight

INDY (121)

10 lbs. (4.54 kg)

16 in. (40 cm)

ahead of rear

idler shaft

7/8-1 1/8 in.

(2.2-2.9 cm)

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

limber.

1. Turn the engine off.

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

3. Place the recommended weight or downward pressure on the track

at the specified distance (see chart) ahead of the center of the rear

idler wheel.

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

112

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Track Maintenance

Track Tension

5. Check for specified slack between the wear surface of the track clip

and the plastic slider. Refer to the Track Tension Data Chart on page

112.

If the track needs adjustment:

6. Loosen the rear idler shaft bolt.

7. Loosen the locknuts.

Slack Measurement

Adjusting Screw

Lock Nut

Shaft

Bolt

Track

16 inches

(40 cm)

10 lbs. (4.54 kg)

8. Tighten or loosen the track adjusting screws to provide equal

adjustment on both sides of the track.

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

TIP:Check more frequently when the snowmobile is new.

10. Start the engine and slowly rotate the track at least five revolutions.

Let the track come to a stop (do not apply brakes).

11. Check track alignment (see page 114) 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).

113

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Track Maintenance

Track Alignment

Periodically check that the track is centered and running evenly on the

slide rails. Misalignment will cause excessive wear to the track and slide

rail.

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

ground.

2. Start the engine and apply a small amount of throttle until the track

turns slowly at least five complete revolutions. Stop the engine and

let the track come to a stop (do not apply brakes).

3. Inspect track alignment by

looking through the track

window to make sure the

rails are evenly spaced on

each side. If the track runs

to the left, loosen the idler

shaft bolts, then loosen the

left locknut and tighten the

left adjusting bolt. If the

track runs to the right,

loosen the idler shaft bolts,

then loosen the right

locknut and tighten the

right adjusting bolt.

4. After adjustments are

Rail

complete, tighten the

locknuts and torque idler

shaft bolts to 35 ft-lbs

(47.5 Nm).

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

114

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Steering System

Steering Inspection

Each week, or before a long ride, check all steering system fasteners and

tighten if necessary.

115

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MAINTENANCE

Steering System

Ski Alignment

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

control, resulting in serious injury or death. Do not attempt to change the ski

alignment or toe adjustment. See your POLARIS dealer.

If the steering feels heavy, or if the snowmobile seems to pull or dart to

the side, ski alignment may need adjustment. Refer to the service

manual or see your dealer for this service.

Ski Toe Settings

WARNING! Improper ski toe adjustment may cause loss of steering control,

resulting in serious injury or death. Do not attempt to change toe adjustment.

See your POLARIS dealer.

The skis on your snowmobile are set with a small amount of toe-out at

the factory. You can inspect the toe setting by following the procedure

below. If adjustments are required, refer to the service manual or see

your dealer for this service.

1. Place the handlebars in a straight-ahead position.

2. With only vehicle weight compressing the suspension, measure 10

inches (25.4 cm) forward from the center of the ski mounting bolt.

See illustration. At this point, measure between the skis. This is

measurement X.

3. Perform the same measurement rearward from the center of the ski

mounting bolt. This is measurement Y.

4. The X measurement should be 1/8-1/4 inch (3-6 mm) greater than

the Y measurement. If the skis are misaligned, see your dealer for

alignment correction.

10 in.

(25.4 cm)

10 in.

(25.4 cm)

116

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Steering System

Ski Skags

WARNING! Worn skis and/or skags will adversely affect handling. Loss of

vehicle control may result, causing serious injury or death. See your dealer's

studding chart for recommended skags. If you install longer or more aggressive

carbide skags than the original equipment, it may also be necessary to add track

studs to maintain proper vehicle control while turning on hard-packed snow or

ice.

Check skags before each use of the snowmobile to ensure positive

steering characteristics. Skags must be replaced when worn to half their

original diameter.

TIP:Carbide skags must be replaced if any abnormal wear or chipping is found.

Skag Replacement

1. Raise and support the front of the

snowmobile so the skis are

approximately 6 inches (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.

Skag

5. Reverse the steps to install a skag.

Rail Slide Wear

For ease of inspection, all

POLARIS rail slides have a wear

limit indicator groove to indicate

the minimum permissible slide

thickness. Replace the rail slides if

Minimum

Thickness

they are worn to the top of the

groove at any point along their

length. Failure to do so may result

in permanent damage to the track

or rails.

Replace when

worn to top of

groove

117

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MAINTENANCE

Battery (if equipped)

WARNING! Improperly connecting or disconnecting battery cables can result in

an explosion and cause serious injury or death. When removing the battery,

always disconnect the negative (black) cable first. When reinstalling the battery,

always connect the negative (black) cable last.

Battery Removal

1. Remove the right side panel to access the battery. See page 95.

2. Disconnect the black (negative) battery cable first.

3. Disconnect the red (positive) battery cable last.

4. Remove the battery.

Battery Installation

When installing a new battery, make sure it's fully charged prior to its

initial use. Using a new battery that has not been fully charged can

damage the battery and result in a shorter life. It can also hinder vehicle

performance. Follow the battery charging instructions on page 119

before installing the battery.

1. Ensure that the battery is fully charged.

2. Set the battery in the battery holder.

3. Connect and tighten the red (positive) cable first.

4. Connect and tighten the black (negative) cable last.

5. Verify that cables are properly routed.

6. Reinstall the side panel.

Battery Storage

Whenever the vehicle is not used for a period of three months or more,

remove the battery from the vehicle, ensure that it's fully charged, and

store it out of the sun in a cool, dry place. Check battery voltage each

month during storage and recharge as needed to maintain a full charge.

Tip: Battery charge can be maintained by using a POLARIS Battery Tender™

charger or by charging about once a month to make up for normal self-

discharge. Battery Tender™ can be left connected during the storage

period, and will automatically charge the battery if the voltage drops below a

pre-determined point.

118

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MAINTENANCE

Battery (if equipped)

Battery Charging

The following battery charging instructions apply only to the

installation of a sealed battery. Read all instructions before proceeding

with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed

and fully charged at the factory. Do not ever pry the sealing strip off or

add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to

keep it fully charged. Since the battery is sealed and the sealing strip

cannot be removed, you must use a voltmeter or multimeter to measure

DC voltage.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully

charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps

or less until the battery voltage is 12.8 or greater.

Tip: When using an automatic charger, refer to the charger manufacturer's

instructions for recharging. When using a constant current charger, use the

following guidelines for recharging.

WARNING! An overheated battery may explode, causing severe injury or

death. Always watch charging times carefully. Stop charging if the battery

becomes very warm to the touch. Allow it to cool before resuming charging.

Tip: Always verify battery condition before and 1-2 hours after the end of

charging.

Charge Time

State of

Charge

(Using constant current

Voltage

Action

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

None, check at 3

mos. from date of

manufacture

None required

75%-100%

12.5-12.8 volts

May need slight

charge, if no

3-6 hours

charge given,

check in 3 months

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less Needs charge with

desulfating charger

At least 20 hours

119

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MAINTENANCE

Fall Tune-Up

For maximum performance, arrange for a fall service tune-up with your

POLARIS dealer. His experienced and trained service technician will

keep your snowmobile in peak operating condition.

Transporting the Snowmobile

Whenever the snowmobile is transported:

1. Be sure the fuel cap and oil cap are installed correctly.

2. Tie the snowmobile to the transporting unit securely using suitable

straps.

3. Remove the ignition key to prevent loss.

Extended Storage

Off-season or extended storage of your snowmobile requires preventive

measures to aid against deterioration and to prolong the useful life of

many components. See page 126 for the part numbers of POLARIS

products.

Cleaning and Preservation

Proper storage starts with cleaning, washing, and waxing the hood, side

panels, chassis, and plastic parts. Wipe down remaining surfaces with a

damp cloth. Clean and touch up with paint any rusted or previously

painted surfaces. Be sure that corrosive salt and acids are removed from

surfaces before beginning preservation with waxes and rust inhibitors

(grease, oil or paint).

The snowmobile should be stored in a dry garage or shed, out of direct

sunlight, and covered with a fabric snowmobile cover. Plastic tarp may

cause condensation to form and damage snowmobile components.

120

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MAINTENANCE

Extended Storage

Controls and Linkage

Lubricate all bushings and cables as outlined in the Periodic

Maintenance Table beginning on page 92.

Clutch and Drive System

Remove the drive belt and store in a cool dry location. Do not lubricate

clutch components, except the driven clutch shaft bushing as outlined in

the Master Repair Manual. See your dealer.

Engine Protection

Proper preparation of the engine and fuel system is vital to the

prevention of rust and corrosion on precision engine parts during

storage. Whenever the snowmobile is stored for a period of more than

60 days, the engine must be fogged with fogging oil. Follow the engine

fogging instructions provided on the container.

Always add Carbon Clean or a fuel conditioner/stabilizer to the fuel

tank. Follow the instructions on the container, running the engine for

five minutes to get additives through the entire fuel system. Top off with

fresh fuel. Do not allow the snowmobile to run out of fuel.

Electrical Connections

Replace worn or frayed electrical wire and connectors. Be sure wiring

harness is properly secured away from sharp edges, steering linkage,

moving parts, and hot exhaust parts.

Track and Suspension

Moderate track tension should be maintained during summer storage.

The snowmobile should be supported off the ground to allow the track

to hang freely.

121

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SPECIFICATIONS

600 INDY

Capacities and Dimensions

Body Style

PRO-RIDE

Rider Capacity

Coolant Capacity

Chaincase Oil Capacity

Fuel Tank Capacity

Gearcase Oil Capacity

Oil Capacity

5 qts. (4.7 l)

9 oz. (266.2 ml)

11.5 gal. (43.5 l)

N/A

3.8 qts. (3.6 l)

48 in. (122 cm)

114 in. (289 cm)

48 in. (122 cm)

Hayes Phantom

Height

Length

Designed Width

Brake Type

Drive Clutch Center Distance 11.5 in. (29 cm)

Drive Belt P/N

3211122

Drive Clutch Type

Driven Clutch Type

Reverse Transmission

P-85

Team LWT

Electronic Reverse

Engine and Cooling

Engine

S5118-6044-OS6G

Displacement

599 cc

Cylinders

Bore x Stroke (mm)

Alternator Output

Recommended Engine Oil

Throttle Body

77.25 x 64

400 watt

VES

1204816

Throttle Body Bore Size

Idle RPM

46mm

1700 +/- 200

Rated Operating RPM

Cooling

8250 +0/-250

Liquid

Ignition Type

CDI

Ignition Timing

Spark Plug / Gap

Recommended Fuel Octane

18° @ idle 1700 RPM w/120°F (49°C) water temp

BPR 9ES /.027 inches (0.7 mm)

91 Recommended (87 Minimum)

122

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SPECIFICATIONS

600 INDY (Non-Electric Start Models)

Clutching Chart

ALTITUDE

Meters

(Feet)

Chaincase

Gearing/

Pitch

DriveClutch DriveClutch Driven Clutch

Driven

Helix

Shift Weight

Spring

*Shaded cells indicate factory settings.

0-600

(0-2000)

10-64

(1321585)

600-1200

(2000-4000)

10-62

(1321586)

22:40

72 Pitch

1200-1800

(4000-6000

10-60

56/42/36

LWER

(5135403)

(1321587)

120/310

(7043681)

RED/BLK

(7043058)

1800-2400

(6000-8000)

10-58

(1321588)

2400-3000

(8000-10000)

10-56

(1321684)

20:41

72 Pitch

3000-3600

(10000-12000)

10 AL

(1321531)

600 INDY (Electric Start Models)

Clutching Chart

ALTITUDE

Chaincase

Gearing/

Pitch

DriveClutch DriveClutch Driven Clutch

Meters

Driven

Helix

Shift Weight

Spring

(Feet)

*Shaded cells indicate factory settings.

0-600

(0-2000)

10-64

(1321585)

600-1200

(2000-4000)

10-62

(1321586)

22:40

72 Pitch

1200-1800

(4000-6000

10-60

56/42/36

LWER

(5135403)

(1321587)

Black/Green

(7042083)

RED/BLK

(7043058)

1800-2400

(6000-8000)

10-58

(1321588)

2400-3000

(8000-10000)

10-56

(1321684)

20:41

72 Pitch

3000-3600

(10000-12000)

10 AL

(1321531)

123

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SPECIFICATIONS

800 INDY

Capacities and Dimensions

Body Style

PRO-RIDE

Rider Capacity

Coolant Capacity

Chaincase Oil Capacity

Fuel Tank Capacity

Gearcase Oil Capacity

Oil Capacity

5 qts. (4.7 l)

9 oz. (266.2 ml)

11.5 gal. (43.5 l)

N/A

3.8 qts. (3.6 l)

48 in. (122 cm)

114 in. (289 cm)

48 in. (122 cm)

Hayes Phantom

Height

Length

Designed Width

Brake Type

Drive Clutch Center Distance 11.5 in. (29 cm)

Drive Belt P/N

3211115

Drive Clutch Type

Driven Clutch Type

Reverse Transmission

P-85

Team Lightweight

Electronic Reverse

Engine and Cooling

Engine

S5123-8044-OS8G

Displacement

794 cc

Cylinders

2 Monoblock

Bore x Stroke (mm)

Alternator Output

Recommended Engine Oil

Throttle Body

85 x 70

400 watt

VES

1204815

Throttle Body Bore Size

Idle RPM

48mm

1700 +/- 200

Rated Operating RPM

Cooling

8250 +0/-250

Liquid

Ignition Type

CDI

Ignition Timing

Spark Plug / Gap

Recommended Fuel Octane

18° @ idle 1700 RPM w/120°F (49°C) water temp

BPR 9ES /.027 inches (0.7 mm)

91 Recommended (87 Minimum)

124

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SPECIFICATIONS

800 INDY

Clutching Chart

ALTITUDE

Meters

(Feet)

Chaincase

Gearing/

Pitch

Drive Clutch Drive Clutch Driven Clutch

Driven

Helix

Shift Weight

Spring

*Shaded cells indicate factory settings.

0-600

(0-2000)

10-66

(1321584)

23:39

72 Pitch

600-1200

(2000-4000)

10-64

(1321585)

120/310 Black

(7043681)

1200-1800

(4000-6000

10-62

22:40

72 Pitch

(1321586)

RED/BLK

(7043058)

(64/42/36) LW

(5135401)

1800-2400

(6000-8000)

10-60

(1321587)

2400-3000

(8000-10000)

10-60

(1321587)

140/330

(7043342)

20:41

72 Pitch

3000-3600

(10000-12000)

10-58

(1321588)

800 INDY International

Clutching Chart

ALTITUDE

Meters

(Feet)

Chaincase

Gearing/

Pitch

Drive Clutch Drive Clutch Driven Clutch

Driven

Helix

Shift Weight

Spring

*Shaded cells indicate factory settings.

0-600

(0-2000)

10-66

(1321584)

600-1200

(2000-4000)

10-64

(1321585)

120/310 Black

(7043681)

22:40

72 Pitch

1200-1800

(4000-6000

10-62

(1321586)

RED/BLK

(7043058)

(64/42/36) LW

(5135401)

1800-2400

(6000-8000)

10-60

(1321587)

2400-3000

(8000-10000)

10-60

(1321587)

140/330

(7043342)

20:41

72 Pitch

3000-3600

(10000-12000)

10-58

(1321588)

125

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricants

Fogging Oil (12 oz. Aerosol)

2870791

2878243

2878191

2877882

2877953

2877883

2877884

VES RACE 2-Cycle Engine Oil (qt./.95 l)

VES RACE 2-Cycle Engine Oil (gal./3.8 l)

VES 2-Cycle Oil (qt./.95 l)

VES 2-Cycle Engine Oil (2 qt./1.9 l)

VES 2-Cycle Engine Oil (gal./3.8 l)

VES 2-Cycle Engine Oil (2.5 gal./9.5 l)

Chaincase Lubricants

2873105

2873106

SCL - Synthetic Chaincase Lubricant (qt./.95 l)

SCL - Synthetic Chaincase Lubricant (gal./3.8 l)

Grease/Specialized Lubricants

Grease Gun Kit, All Season (3 oz./89 ml)

All Season Grease (3 oz./89 ml cartridge)

All Season Grease (14 oz./414 ml cartridge)

Dielectric Grease (Nyogel™)

Coolant

2871312

2871322

2871423

2871329

2880514

2880513

Antifreeze 50/50 Premix (qt./.95 l)

Antifreeze 50/50 Premix (gal./3.8 l)

Additives/Miscellaneous

2871326

2870652

2872189

2872893

2870505

2872889

2872890

2878018

Carbon Clean

Fuel Stabilizer

DOT4 Brake Fluid

Engine Degreaser

Isopropyl Fuel De-Icer

Brake and Clutch Cleaner

Carburetor and Throttle Body Cleaner

Shock Thread Spray Lubricant

126

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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- Drive clutch binding • SEE YOUR DEALER.

ating RPM during

Driven clutch

malfunction

• SEE YOUR DEALER.

• Replace the drive belt.

• SEE YOUR DEALER.

• Replace the drive belt.

acceleration or load

variations

Harsh drive clutch

engagement

Drive belt worn or

too narrow

Excessive belt/

sheave clearance

Drive belt turns over Wrong belt for

application

Clutch alignment out • SEE YOUR DEALER.

of spec

Engine mount

broken or loose

• Inspect and replace. SEE YOUR

DEALER.

Machine fails to

move

Clutch jammed

• Check for twisted belt or broken

spring. SEE YOUR DEALER.

Track jammed

• Foreign object may be caught or the

rail slide melted to the track clips

due to lack of lubrication.

• Track may be iced up or frozen to

the ground.

Chaincase sprocket

or chain jammed or

broken

• Chain is loose or broken or chain

tightener is loose. SEE YOUR

DEALER.

127

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TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause Solution

Noise in drive

system

Broken drive clutch • SEE YOUR DEALER.

components

Bearing failure/

chaincase, jackshaft,

or front driveshaft

• SEE YOUR DEALER.

Drive belt surface

flat spots

• Inspect and replace as needed.

Drive chain loose

• Inspect and adjust (or replace).

• SEE YOUR DEALER.

Drive chain worn,

sprocket teeth

broken

Poor low RPM

performance

Worn drive belt

• Inspect and replace as needed.

• SEE YOUR DEALER.

Excessive belt/

sheave clearance

Sticky clutch

• SEE YOUR DEALER.

Poor fuel quality

Seized engine

• Use 87-91 octane fuel (or higher).

Engine doesn't turn

• SEE YOUR DEALER. Seizure is a

result of poor lubrication,

inadequate fuel supply, broken parts

or improper cooling.

Hydrostatic lock

• Fuel may have entered the crankcase

while the vehicle was standing or

being transported. SEE YOUR

DEALER to correct the cause. Drain

plug(s) are located on the lower

crankcase for emergency draining.

128

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TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause Solution

Engine turns but fails Faulty ignition

to start

• Install new spark plug(s). If engine

still fails to start, check for spark. If

there's no spark, SEE YOUR

DEALER.

No fuel to engine

• Make sure the fuel valve is on.

• Make sure tank contains fuel.

• Ice may be in the fuel line, filter or

pump. Add isopropyl alcohol to the

fuel system.

• SEE YOUR DEALER.

Poor engine

compression

• This indicates a major engine

problem that must be repaired before

operating. SEE YOUR DEALER.

Engine lacks power

Fouled or defective

spark plug(s)

• Replace the plug(s).

Fuel filter (loss of

high RPM power)

• SEE YOUR DEALER.

Plugged fuel filter or • SEE YOUR DEALER.

tank pick-up sock

Incorrect clutching

Faulty plug(s)

Fuel System

• SEE YOUR DEALER.

• Change plug(s).

Engine continually

backfires

• Dirt or ice may be in the fuel system

(deicer should be added to non-

ethanol fuel at all times for

assurance against fuel line icing).

Incorrect throttle

freeplay or faulty

switch

• SEE YOUR DEALER.

Engine requires

more than normal

pulls to start

Poor fuel

• Replace with fresh winter fuel.

• SEE YOUR DEALER.

Not enough fuel

getting to engine

Plugged fuel filter or • SEE YOUR DEALER.

tank pick-up sock

129

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TROUBLESHOOTING

Rear Suspension Troubleshooting

Problem

Solution

Rear suspension

bottoms too easily

• Adjust torsion spring preload to achieve proper static sag

(see page 62).

• Change torsion spring to stiffer optional spring (see your

dealer).

• Revalve rear track shock (see your dealer).

• Rotate RRSS to higher position (see page 66).

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 62).

• Change torsion spring to softer optional spring (see your

dealer).

• Check track tension (see page 112).

• Rotate RRSS to lower position (see page 66).

Machine darts from

side to side

• See your dealer for ski alignment inspection.

• 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 62).

• Check rail slide/replace if worn (see page 117).

• Install Accu-Trak dual skags (see your dealer).

Front end pushes

• Check for worn skags.

• Check for binding front suspension shafts and steering

components, grease all pivot points (elevate front of

machine).

• Set static sag (see page 62).

• Install single skag (see your dealer).

• Increase IFS preload (if equipped) (see page 60).

• Rotate RRSS to higher position (see page 66).

Steering is heavy

• Make sure spindles and all steering components turn freely.

• See your dealer for ski alignment inspection.

• Check skags and skis for damage.

• Set static sag (see page 62).

130

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TROUBLESHOOTING

Drive Belt Troubleshooting

Belt Wear/Burn Diagnosis

Causes

Solutions

Driving at low RPM

• Drive at higher RPMs. Gear the machine down. Check

belt deflection.

Insufficient warm-up

Towing at low RPM

• Warm the engine at least five minutes. Take the drive

belt off the snowmobile in extremely cold weather and

warm it up. Break snowmobile loose from the snow.

• Do not tow in deep snow. Use fast, aggressive throttle

to engage clutch.

Riding with high RPM

and slow speed (8000

RPM/10 MPH/16 km/h)

• Lower the gear ratio. Reduce RPM. Avoid riding in

high ambient temperatures. Check for snow ingestion.

Ice and snow build-up

between track and tunnel

• Warm the engine at least five minutes. Take the drive

belt off the snowmobile in extremely cold weather and

warm it up. Break snowmobile loose from the snow.

Poor engine performance • Check for fouled plugs and water, ice or dirt in the fuel

tank or fuel line.

Loading snowmobiles

onto trailers

• Skis may gouge into trailers and prevent the drivetrain

from spinning properly. Use enough speed to drive the

snowmobile completely onto the trailer. Push and pull

it to finish loading if necessary.

Clutch malfunction

• Inspect clutch components. See your dealer.

• Use fast, aggressive throttle to engage clutch.

Slow, easy clutch

engagement

131

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WARRANTY

Service and Warranty Information

Obtaining Service and Warranty Assistance

Read and understand the service data and the POLARIS warranty information

contained in this manual. Contact your POLARIS dealer for replacement parts,

service or warranty. Your dealer receives frequent updates on changes,

modifications and tips on snowmobile maintenance, which may supersede

information contained in this manual. Your dealer is also familiar with

POLARIS policies and procedures and will be happy to assist you.

When contacting us about parts, service, or warranty, always provide the

following information:

1. Serial number

2. Model number

3. Dealer name

4. Date of purchase

5. Details of trouble experienced

6. 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 & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

132

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WARRANTY

Limited Warranty

POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a

12 MONTH LIMITED WARRANTY on all components of your POLARIS vehicle

against defects in material or workmanship. This warranty covers parts and labor

charges for repair or replacement of defective parts and begins on the date of purchase

by the original retail purchaser. This warranty is transferable to another owner during the

warranty period through a POLARIS dealer, but any such transfer will not extend the

original term of the warranty. The duration of this warranty may vary by international

region based upon local laws and regulations.

THIS WARRANTY MAY BE VOIDED BY ANY UNAPPROVED MODIFICATIONS

TO THIS VEHICLE THAT AFFECT POWERTRAIN, EXHAUST, CHASSIS OR

SUSPENSION.

Promotional warranties are sometimes offered by POLARIS, including but not limited

to:

• Two-year extended engine coverage

• Two-year powertrain coverage

• Extended service contract

See your dealer for details and separate terms and conditions for any promotional

warranties.

Registration

At the time of sale, the Warranty Registration Form must be completed by your dealer

and submitted to POLARIS within ten days of purchase. 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 your proof of warranty coverage. If you have not signed the original registration

and received the customer copy, please contact your dealer immediately. NO

WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS

REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is

very important in ensuring trouble-free operation. Purchasing a machine in the crate or

without proper dealer set-up will void your warranty coverage.

133

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WARRANTY

Warranty Coverage and Exclusions

Limitations of Warranties and Remedies

This POLARIS Limited Warranty excludes any failures that are not caused by a defect

in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF

DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental

damage, normal wear and tear, abuse or improper handling. This warranty also does not

cover any vehicle, component or part that has been altered structurally, modified,

neglected, improperly maintained or used for racing, competition or purposes other than

for which it was designed.

This warranty also excludes failures resulting from improper lubrication; improper

engine timing; improper fuel; surface imperfections caused by external stress, heat, cold

or contamination; operator error or abuse; improper component alignment, tension,

adjustment or altitude compensation; failure due to snow, water, dirt or other foreign

substance ingestion/contamination; improper maintenance; modified components; use

of aftermarket components; 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.

This warranty excludes damages or failures caused by abuse, accident, fire or any other

cause other than a defect in materials or workmanship and provides no coverage for

consumable components, general wear items or any parts exposed to friction surfaces,

stresses, environmental conditions and/or contamination for which they were not

designed or not intended, including but not limited to the following items:

Skis

Ski wear rods

Tracks

Slide rails

Suspension components

Brake components

Seat components

Clutches and components

Steering components

Batteries

Finished and unfinished surfaces

Carburetor/Throttle body components

Engine components

Drive belts

Hydraulic components

Circuit breakers/Fuses

Electronic components

Spark Plugs

Light bulbs/Sealed beam lamps

Idler wheels

Sealants

Lubricants

Coolant

Filters

Fuel

134

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WARRANTY

Warranty Coverage and Exclusions

Limitations of Warranties and Remedies

Lubricants and Fluids

1. Mixing oil brands or using non-recommended oil may cause engine damage. We

recommend the use of POLARIS engine oil.

2. Damage or failure resulting from the use of non-recommended lubricants or fluids is

not covered by this warranty.

This warranty provides no coverage for personal loss or expense, including mileage,

transportation costs, hotels, meals, shipping or handling fees, product pick-up or

delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or

personal time.

THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT

POLARIS’ OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE

MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN

THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON

FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY

TO ANY PERSON FOR INCIDENTAL, 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. THIS EXCLUSION OF CONSEQUENTAL,

INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL

SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS

ESSENTIAL PURPOSE.

THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS

EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED

WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED

WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE

ABOVE 12 MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS

WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT

PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR

CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION

OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY

TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.

135

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WARRANTY

How to Obtain Warranty Service

If your vehicle requires warranty service, you must take it to a POLARIS Servicing

Dealer. 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 suggests that you use

your original selling dealer; however, you may use any POLARIS Servicing Dealer to

perform warranty service.

In the country where your product 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 product was purchased,

warranty and service bulletin repairs may be requested from any authorized POLARIS

dealer that sells the same line as your product.

Outside the country where your product was purchased:

If you are traveling temporarily outside the country where your product was purchased,

you should take your product to an authorized POLARIS dealer. You must show the

dealer photo identification from the country of the selling dealer’s authorized location as

proof of residence. Upon residence verification, the servicing dealer will be authorized

to perform the warranty repair.

If you move:

If you move to another country, be sure to contact POLARIS Customer Assistance and

the customs department of the destination country before you move. Product

importation rules vary considerably from country to country. You may be required to

present documentation of your move to POLARIS in order to continue your warranty

coverage. You may also be required to obtain documentation from POLARIS in order to

a local POLARIS dealer in your new country immediately after you move to continue

your warranty coverage and to ensure that you receive information and notices regarding

your vehicle.

If you purchase from a private party:

If you purchase a POLARIS product from a private party, to be kept and used outside of

the country in which the product was originally purchased, all warranty coverage will be

denied. You must nonetheless register your product under your name and address with a

local POLARIS dealer in your country to ensure that you receive safety information and

notices regarding your product.

136

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WARRANTY

Exported Products

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO

WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS

SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED

LOCATION. This policy does not apply to products that have received authorization for

export from POLARIS. Dealers may not give authorization for export. You should

consult an authorized dealer to determine this product’s warranty or service coverage if

you have any questions. This policy does not apply to products registered to government

officials or military personnel on assignment outside the country of the selling dealer’s

authorized location. This policy does not apply to safety bulletins.

Notice

If your product is registered outside of the country where it was purchased and you have

not followed the procedure set above, your product will no longer be eligible for

warranty or service bulletin coverage of any kind, other than safety bulletins. Products

registered to Government officials or military personnel on assignment outside of the

country where the product was purchased will continue to be covered by the Limited

Warranty.

Please work with your dealer to resolve any warranty issues. Should your dealer require

any additional assistance, they will contact the appropriate person at POLARIS.

This warranty gives you specific legal rights, and you may also have other rights which

vary from state to state or in different countries. If any of the above terms are void

because of federal, state, local law, all other warranty terms will remain in effect.

For questions call POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

137

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

This Emissions Limited Warranty is in addition to the POLARIS standard Limited

Warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first

purchased, this emissions-certified vehicle is designed, built and equipped so it

conforms with applicable U.S. Environmental Protection Agency emission regulations.

POLARIS warrants that the vehicle is free from defects in materials and workmanship

that would cause it to fail to meet these regulations.

The warranty period for this emissions-certified vehicle starts on the date the vehicle is

first purchased and continues for a period of 200 hours of engine operation; 4,000

kilometers (2,485 miles) of vehicle travel; or 30 calendar months from the date of

purchase, whichever comes first.

This Emissions Limited Warranty covers components if their failure increases the

vehicle’s regulated emissions, and it covers components of systems if their only purpose

is to control emissions. Repairing or replacing other components not covered by this

warranty is the responsibility of the vehicle owner. This Emissions Limited Warranty

does not cover components if their failure does not increase the vehicle’s regulated

emissions.

For exhaust emissions, emission-related components include any engine parts related to

the following systems:

•

Air-induction system

Fuel system

•

Ignition system

Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust

emissions:

•

Aftertreatment devices

Crankcase ventilation valves

•

Sensors

Electronic control units

The following parts are considered emission-related components for evaporative

emissions:

•

Fuel Tank

Fuel Cap

Fuel Line

Fuel Line Fittings

Clamps*

Pressure Relief Valves*

Control Valves*

Control Solenoids*

Electronic Controls*

•

Vacuum Control Diaphragms*

Control Cables*

Control Linkages*

Purge Valves

Vapor Hoses

Liquid/Vapor Separator

Carbon Canister

Canister Mounting Brackets

Carburetor Purge Port Connector

*As related to the evaporative emission control system.

138

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

The exclusive remedy for breach of this Limited Warranty shall be, at the exclusive

option of POLARIS, repair or replacement of any defective materials, components or

products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

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. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND

SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY

FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL

PURPOSE.

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 STATED IN THIS WARRANTY. Some states do not allow

limitations on how long an implied warranty lasts, so the above limitation may not apply

if it is inconsistent with the controlling state law.

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. This Limited Warranty also does not cover any

engine that has been structurally altered, or when the vehicle has been used in racing

competition. This Limited Warranty also does not cover physical damage, corrosion or

defects caused by fire, explosions or other similar causes beyond the control of

POLARIS.

Owners are responsible for performing the scheduled maintenance identified in the

owner’s manual. POLARIS may deny warranty claims for failures that have been

caused by the owner’s or operator’s improper maintenance or use, by accidents for

which POLARIS has no responsibility, or by acts of God.

Any qualified repair shop or person may maintain, replace, or repair the emission

control devices or systems on your vehicle. POLARIS recommends that you contact an

authorized POLARIS dealer to perform any service that may be necessary for your

vehicle. POLARIS also recommends that you use only POLARIS parts. It is a potential

violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer

reduces the effectiveness of the vehicle’s emission controls. Tampering with emission

controls is prohibited by federal law.

If you have any questions regarding your warranty rights and responsibilities, please

contact POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

139

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MAINTENANCE LOG

Present this section of your manual to your dealer each time your snowmobile is

serviced. This will provide you and future owners with an accurate log of maintenance

and services performed on the snowmobile.

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

140

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

141

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . 28

Air Pollution . . . . . . . . . . . . . . . . . . . 6

Avalanches. . . . . . . . . . . . . . . . . . . . 15

Drive Belt

Break-In. . . . . . . . . . . . . . . . . . . 80

Safety. . . . . . . . . . . . . . . . . . . . . 18

Drive Belt Adjustment. . . . . . . . . . . 109

Drive Belt Condition . . . . . . . . . . . . 109

Drive Belt Deflection. . . . . . . . . . . . 109

Drive Belt Installation . . . . . . . . . . . 110

Drive Belt Removal. . . . . . . . . . . . . 110

Drive Chain Tension . . . . . . . . . . . . 103

Driver Awareness . . . . . . . . . . . . . . . 14

Driving Downhill. . . . . . . . . . . . . . . . 17

Driving in Hilly Terrain. . . . . . . . . . . 17

Driving on Slippery Surfaces . . . . . . 16

Driving Responsibly . . . . . . . . . . . . . 19

Battery . . . . . . . . . . . . . . . . . . 118-119

Charging . . . . . . . . . . . . . . . . 119

Installation . . . . . . . . . . . . . . . 118

Removal. . . . . . . . . . . . . . . . . 118

Storage. . . . . . . . . . . . . . . . . . 118

Belt Break-In . . . . . . . . . . . . . . . . . . 80

Brake Lever Travel Inspection . . . . 74

Brakelight Replacement. . . . . . . . . 107

Brakes . . . . . . . . . . . . . . . . 74, 104-106

Brake Fluid . . . . . . . . . . . . . . 105

Components. . . . . . . . . . . . . . 104

Inspection. . . . . . . . . . . . . . . . 104

Lever Travel. . . . . . . . . . . . . . 104

System Bleeding . . . . . . . . . . 106

Break-In Period . . . . . . . . . . . . . . 79-80

Electrical Connections, Storage. . . . 121

Emission Control Information. . . . . . 90

Emissions Limited Warranty. . 138-139

Engine Break-In. . . . . . . . . . . . . . 79-80

Engine Overheating. . . . . . . . . . . . . . 33

Engine Protection for Storage . . . . . 121

Engine Restarting . . . . . . . . . . . . . . . 78

Engine Safety. . . . . . . . . . . . . . . . . . . 10

Engine Starting . . . . . . . . . . . . . . . . . 78

Engine Stop Switch . . . . . . . . . . . . . . 85

Engine-Cooling Actions . . . . . . . . . . 33

Environment Preservation . . . . . . . . . . 6

Exhaust System . . . . . . . . . . . . . . . . 103

Carbide Skags . . . . . . . . . . . . . . . . . 67

Chaincase Oil. . . . . . . . . . . . . . . . . . 97

Cleaning/Preservation for Storage. 120

Clutch Alignment Offset . . . . . . . . 108

Clutch Safety . . . . . . . . . . . . . . . . . . 18

Clutch System . . . . . . . . . . . . . 108-110

Clutch Warning . . . . . . . . . . . . . . . . 21

Clutch/Drive System, Storage . . . . 121

Clutching Chart . . . . . . . . . . . . . . . 123

Cold Weather Drive-Away . . . . . . . 18

Controls and Linkage, Storage . . . 121

Coolant. . . . . . . . . . . . . . . . . . . . . . 101

Coolant Level. . . . . . . . . . . . . . . . . 101

Cooling System . . . . . . . . . . . . 101-102

Cooling System, Bleeding . . . . . . . 102

Customer Service. . . . . . . . . . . . . . 132

Fasteners, Hood and Side Panel . . . . 76

Fluid Change, Chaincase. . . . . . . . . . 97

Fluid Level

Brake Fluid . . . . . . . . . . . . . . . 105

Coolant . . . . . . . . . . . . . . . . . . 101

Oil Bottle . . . . . . . . . . . . . . . . . . 84

Front Rear Scissor Stop. . . . . . . . . . . 64

Front Suspension Adjustments . . 59-60

Front To Rear Coupling. . . . . . . . . . . 64

FRSS . . . . . . . . . . . . . . . . . . . . . . . . . 64

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Fuel Filter . . . . . . . . . . . . . . . . . . . . 100

Fuel Lines . . . . . . . . . . . . . . . . . . . . 100

Fuel Premix (Initial Fill) . . . . . . . . . . 79

Fuel Pump . . . . . . . . . . . . . . . . . . . . 100

Fuel Recommendation. . . . . . . . . . . . 82

Fuel System Deicers . . . . . . . . . . . . . 83

Fuel Type Selection. . . . . . . . . . . . . . 29

Fuel Warnings . . . . . . . . . . . . . . . . . . 82

DET . . . . . . . . . . . . . . . . . . . . . . . 30-31

Diagnostic Display Codes . . . . . . 57-58

Diagnostic Display Mode

Digital/Analog Gauge . . . . . . . 43

MFD (if equipped). . . . . . . . . . 56

Disabled Operators . . . . . . . . . . . . . 12

Display Units, Standard/Metric

Digital/Analog Gauge . . . . . . . 37

MFD (if equipped). . . . . . . . . . 50

142

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INDEX

Handlebar Adjustments. . . . . . . . . . . 70

Handlebar Angle. . . . . . . . . . . . . . . . 70

Handlebar Component Fasteners . . . 68

Handlebar Control Adjustment, Left 69

Handlebar Position . . . . . . . . . . . . . . 70

Headlight Adjustment. . . . . . . . . . . . 28

Headlight Lamp Replacement . . . . 107

Hood Fasteners . . . . . . . . . . . . . . . . . 76

Hood/Side Panel Access . . . . . . . . . . 95

Hot Surface Warning . . . . . . . . . . . . 23

Noise. . . . . . . . . . . . . . . . . . . . . . . . . . 6

Odometer/Engine Hour Display

Digital/Analog Gauge. . . . . . . . 36

MFD (if equipped) . . . . . . . . . . 49

Oil Change, Chaincase . . . . . . . . . . . 97

Oil Filter . . . . . . . . . . . . . . . . . . . . . 100

Oil Injection System . . . . . . . . . . . . . 80

Oil Level, Low . . . . . . . . . . . . . . . . . 84

Oil Lines . . . . . . . . . . . . . . . . . . . . . 100

Oil Recommendations . . . . . . . . . . . 79

Operating in Deep Snow. . . . . . . . . . 16

Operation Warning . . . . . . . . . . . 24-25

Operator Safety. . . . . . . . . . . . . . . 8-20

Overheating, Engine . . . . . . . . . . . . . 33

Ice and Snow Build-up . . . . . . . . . . . 16

IFS. . . . . . . . . . . . . . . . . . . . . . . . . . . 59

IFS Adjustment Options . . . . . . . . . . 59

IFS Components . . . . . . . . . . . . . . . . 59

Ignition Lock System

Digital/Analog Gauge. . . . . 38-42

MFD (if equipped) . . . . . . . 51-55

Inadequate Snow Conditions . . . . . . 16

Independent Front Suspension . . . . . 59

Indicator Lamps, Digital/Analog . . . 35

Indicator Lights, MFD . . . . . . . . . . . 45

Information Display Area

Digital/Analog Gauge. . . . . . . . 36

MFD (if equipped) . . . . . . . . . . 48

Inspection, Pre-Ride . . . . . . . . . . . . . 71

Instrument Cluster

Digital/Analog . . . . . 34-43, 57-58

MFD (if equipped) . . . . . . . 44-58

Intake Filters . . . . . . . . . . . . . . . . . . 100

Intake Silencer . . . . . . . . . . . . . . . . . 18

Parking Brake Lever Lock . . . . . . . . 75

Passenger Warning . . . . . . . . . . . . . . 22

Polaris Products and Part Numbers 126

Preload, IFS Shock Spring . . . . . . . . 60

Pre-Ride Checklist . . . . . . . . . . . . . . 71

Pre-Ride Suspension Inspection . . . . 72

Pressure Cap Warning . . . . . . . . . . . 23

Rail Slide Wear. . . . . . . . . . . . . . . . 117

Rear Rear Scissor Stop . . . . . . . . . . . 65

Rear Suspension Adjustments . . 61-66

Rear To Front Coupling . . . . . . . . . . 65

Recoil Rope Inspection. . . . . . . . . . . 76

Registration, Warranty . . . . . . . . . . 133

Reverse Operation . . . . . . . . . . . 87-88

Reverse Warning . . . . . . . . . . . . . . . 22

Rider Capacity . . . . . . . . . . . . . . . . . 13

Rider Information Center

Digital/Analog Gauge 36-43, 57-58

MFD (if equipped) . . . . . . . 46-58

Riding Apparel . . . . . . . . . . . . . . . . . 11

Riding Position . . . . . . . . . . . . . . . . . 10

RRSS. . . . . . . . . . . . . . . . . . . . . . . . . 65

Lights

Headlight Replacement. . . . . . 107

Taillight/Brake Light . . . . . . . 107

Limiter Strap Position. . . . . . . . . . . . 63

Low Oil Level. . . . . . . . . . . . . . . . . . 84

Lubrication . . . . . . . . . . . . . . . . . 96-97

Lubrication, Rear Suspension. . . . . . 96

Maintenance Interval Table . . . . 92-94

Maintenance Program. . . . . . . . . . . . 91

Maintenance Recommendations. . . . . 9

Maneuverability . . . . . . . . . . . . . . . . 18

Metric/Standard Display

Safety Labels . . . . . . . . . . . . . . . 21-24

Safety Symbols . . . . . . . . . . . . . . . . . . 8

Sag . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Security System

Digital/Analog Gauge. . . . . . . . 37

MFD (if equipped) . . . . . . . . . . 50

Digital/Analog Gauge. . . . . 38-42

MFD (if equipped) . . . . . . . 51-55

143

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INDEX

Security System (Ignition Lock) . . . 32

Shock Valving, IFS . . . . . . . . . . . . . 60

Side Panel Access . . . . . . . . . . . . . . 95

Side Panel Fasteners . . . . . . . . . . . . 76

Signal Words . . . . . . . . . . . . . . . . . . . 8

Ski Alignment . . . . . . . . . . . . . . . . 116

Ski Pressure . . . . . . . . . . . . . . . . . . . 63

Ski Skags . . . . . . . . . . . . . . . . . . . . 117

Ski Toe Settings. . . . . . . . . . . . . . . 116

Slide Rail and Track Cooling . . . . . 81

Snow Conditions . . . . . . . . . . . . . . . 16

Spark Plug Condition. . . . . . . . . . . . 99

Spark Plug Inspection . . . . . . . . . . . 99

Spark Plug Recommendations. . . . . 98

Spark Plugs . . . . . . . . . . . . . . . . . 98-99

Speed Display, MFD . . . . . . . . . . . . 48

Spring Preload . . . . . . . . . . . . . . . . . 62

Spring Preload, IFS Shock. . . . . . . . 60

Spring Preload, Rear . . . . . . . . . . . . 62

Standard/Metric Display, MFD . . . . 50

Starting the Engine . . . . . . . . . . . . . 78

Starting the Engine, Restarting . . . . 78

Steering Inspection . . . . . . . . . . . . 115

Steering System . . . . . . . . . . . . 115-117

Steering System Inspection . . . . . . . 76

Stopping, Emergency. . . . . . . . . . . . 88

Storage Procedures . . . . . . . . . 120-121

Storage, Cargo . . . . . . . . . . . . . . . . . 28

Storage, Daily . . . . . . . . . . . . . . . . . 89

Survival Preparation . . . . . . . . . . . . 12

Suspension Coupling . . . . . . . . . . 64-65

Suspension Inspection, Pre-Ride . . . 72

Suspension Lubrication, Rear . . . . . 96

Suspension Performance Tips . . . . . 61

Switches

Tachometer . . . . . . . . . . . . . . . . . . . . 37

Taillight/Brakelight Replacement . . 107

Tether Switch. . . . . . . . . . . . . . . . . . . 77

Throttle Lever . . . . . . . . . . . . . . . . . . 86

Throttle Lever Inspection . . . . . . . . . 73

Throttle Safety Switch. . . . . . . . . . . . 85

Throttle Safety Switch Inspection . . . 73

Torsion Spring Preload . . . . . . . . . . . 63

Towing. . . . . . . . . . . . . . . . . . . . . . . . 89

Track

Alignment . . . . . . . . . . . . . . . . 114

Inspection. . . . . . . . . . . . . . . . . 111

Lubrication. . . . . . . . . . . . . . . . 111

Tension . . . . . . . . . . . . . . 112-113

Track Care for Storage . . . . . . . . . . 121

Track Inspection . . . . . . . . . . . . . . . . 76

Track Maintenance . . . . . . . . . 111-114

Track Safety. . . . . . . . . . . . . . . . . . . . 10

Track Tension . . . . . . . . . . . . . . . . . . 61

Track Warm-Up. . . . . . . . . . . . . . . . . 81

Track Warning. . . . . . . . . . . . . . . . . . 23

Traction Products. . . . . . . . . . . . . . . . 67

Transporting the Snowmobile . . . . . 120

Troubleshooting, Drive Belt . . . . . . 131

Troubleshooting, Engine . . . . . 127-129

Troubleshooting, Rear Suspension . 130

Tune-Up. . . . . . . . . . . . . . . . . . . . . . 120

Vehicle Identification Numbers. . . . . . 7

Wear Strips . . . . . . . . . . . . . . . . . . . . 67

Weight Transfer. . . . . . . . . . . . . . . . . 66

Windchill . . . . . . . . . . . . . . . . . . . . . . 20

Engine Stop Switch . . . . . . . . . 85

Ignition Switch . . . . . . . . . . . . 77

Mode Button . . . . . . . . . . . . . . 36

Mode/Select Buttons . . . . . . . . 44

Mode/Set Switch . . . . . . . . 36, 44

Tether Switch. . . . . . . . . . . . . . 77

Throttle Safety Switch. . . . . . . 85

144

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For your nearest Polaris dealer,

call 1-800-POLARIS (765-2747)

or visit www.polaris.com

Polaris Industries Inc.

2100 Highway 55

Medina, MN 55340

Part No. 9925987 Rev 01

Printed in USA

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