Polaris Offroad Vehicle 600 Rush Pro R User Manual

PMS 419

IMPORTANT NOTICE TO OWNER

Modifications to this snowmobile are not recommended

and may result in voided warranty coverage.

Please read the warranty section of this manual carefully.

600 RUSH® PRO-R

800 RUSH® PRO-R

Snowmobile Owner's Manual

for Maintenance and Safety

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WARNING

Read, understand, and follow all of the instructions and safety precautions in

this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

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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

• 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 pro-

duced.

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

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

contains instructions for minor maintenance, but information about

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

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

technician.

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

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

vice needs during, and after, the warranty period.

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POLARIS, PERC, PRO-RIDE and RUSH are registered trademarks of POLARIS

Industries Inc.

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

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

ancies may result between the actual vehicle and the information presented in this publi-

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

only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse

of the depictions and/or procedures contained within, whether whole or in part, is

expressly prohibited.

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

translations of the original instructions.

Printed in U.S.A.

2014 600/800 RUSH Owner's Manual

P/N 9924260

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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

features.

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 46

This section includes a Suspension Quick Set-Up Guide and explains

how to make additional suspension adjustments for the perfect riding

experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 60

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

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

general operating procedures.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

This section defines your role, and your dealer's role, in your snowmo-

bile's regular maintenance.

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 115

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 116

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 120

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 133

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

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INTRODUCTION

Important Notes for Owners and Drivers

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

erence. It should remain with the snowmobile when the snowmobile is

sold.

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

resentations. Your model may differ.

Follow the maintenance program outlined in this manual. Preventive

maintenance ensures that critical components of the snowmobile are

inspected by your dealer at specific mileage intervals.

You and your dealer must complete the registration form included with

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

to ensure warranty coverage.

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

clubs.

When teaching inexperienced operators to ride, set up a predetermined

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

snowmobile before allowing them to make longer trips. Teach them

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

safety courses sponsored by local or state organizations.

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INTRODUCTION

Preservation of the Environment

POLARIS is committed to supporting an environmental education cam-

paign. We encourage state and provincial governments across the snow-

belt to adopt rigorous safety training programs that encourage protection

of our environment, including wildlife and vegetation.

Snowmobile clubs and other organizations are working together to pro-

tect our environment. Please support their efforts and operate your

snowmobile with consideration for the protection and preservation of

our environment.

Noise Level

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

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

snowmobile development, recommends that snowmobiles conform to

prescribed sound levels.

POLARIS snowmobiles are engineered to conform to these SAE stan-

dards. Our muffler systems are designed to reduce noise levels and must

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

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

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

turing quieter machines; we ask your help to further reduce the impact

of noise by operating your snowmobile safely and responsibly.

Air Pollution

POLARIS engineers continuously investigate ways to reduce emission

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

tion of potential air pollution.

In addition to our technological research, we encourage government

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

interested parties to work together to develop data on environmental

topics.

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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.

Tunnel VIN

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 sym-

bols 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 81

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 aerody-

namically unstable at speeds higher than those for which it is designed. Loss of

control may occur at higher speeds. Modifications may also create a safety haz-

ard and lead to bodily injury.

The warranty on your entire machine is terminated if any equipment has been

added, or any modifications have been made, to increase the speed or power of

the snowmobile.

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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

STEP

hands, feet, or clothing become entangled

in the track. Be alert when riding, and

remain properly seated to stay clear of the

track. Never hold the snowmobile up or

stand behind it while warming up the track.

A loose track or flying debris could cause

serious injury or death. We recommend

having your dealer perform all track service

and alignment procedures.

Stay Clear of Engine

Never attempt adjustments with the engine running. Turn off the igni-

tion, 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 estab-

lished safety standards.

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

Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania

bear the ECE 22.05 label. The ECE mark consists

of a circle surrounding the letter E, followed by the

distinguishing number of the country which has

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. When-

ever riding a POLARIS vehicle, always wear shatterproof goggles or

use a shatterproof helmet face shield. POLARIS recommends wearing

approved Personal Protective Equipment (PPE) bearing markings such

as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept

clean.

Clothing

Be prepared, be warm and be com-

fortable when riding. Be aware of

the weather forecast, especially the

windchill, and dress accordingly.

See the chart on page 20.

WARNING! Avoid wearing loose

clothing or long scarves, which can

become entangled in moving parts and

cause serious injury. Always wear an

approved helmet and eye protection.

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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 condi-

tions you may encounter. Such equipment may include, but is not lim-

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

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

lular telephone.

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

tection, purchase and carry the following items on your snowmobile as

well:

• Spare Drive Belt

• 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 pas-

senger on this snowmobile.

Excessive Speed

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

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

Always observe all state and local laws governing snowmobile opera-

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

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

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

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

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

two seconds.

Traveling at night requires extra caution. Check headlight and taillight

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

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

minated by the headlight.

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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 crossing railroad tracks

or highways. Steep embankments may

also hide your view. Always leave yourself

a way out.

R R

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

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

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

ciently thick to support the weight and moving force of the snowmobile,

you and your cargo, together with any other vehicles in your party.

Always check with local authorities and residents to confirm ice condi-

tions and thickness over your entire route. Snowmobile operators

assume all risk associated with ice conditions on frozen bodies of water.

When teaching inexperienced operators to ride, set up a predetermined

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

snowmobile before allowing them to make longer trips. Teach them

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

safety courses.

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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 moun-

tainous terrain.

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

lanche advisory to get current weather and snow stability information.

For more information about avalanche training and avalanche condi-

tions, contact local law enforcement in your area, or visit the American

and Canadian online avalanche centers at www.avalanche.org.

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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 snowmo-

bile, 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 dynami-

cally balanced before installation. Any tampering may disrupt this preci-

sion balancing and create an unstable condition.

Cold Weather Drive-Away

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

cially overnight, always make sure the skis and track are loosened from

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

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

safety limits.

Maneuverability

While much control and maneuverability is achieved through the steer-

ing system and skis, maximum control is achieved by the shifting of

your body weight. Maneuverability will change for lighter operators or

snowmobiles designed to carry a load.

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SAFETY

Operator Safety

Driving Responsibly

Every snowmobile handles differently, and even the most docile condi-

tions may become dangerous if operators drive improperly. If you're

new to snowmobiling, acquaint yourself with the snowmobile and with

what it will and won't do under various conditions. Even seasoned driv-

ers should spend some time getting the feel for a snowmobile before

attempting ambitious maneuvers.

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

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

smooth, level area to begin building your operating experience.

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

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

mobile safety course and have an operator's certificate. For their pro-

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

course. Everyone can benefit from the course.

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

Jumping may injure your back because of spinal compression that

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

suspension of your snowmobile have been designed to provide pro-

tection under normal riding conditions. Your snowmobile is not

intended for this kind of use.

• Be courteous to oncoming traffic by dimming your headlights and

reducing your speed.

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

closely). Leave enough distance between snowmobiles to provide

ample stopping room and to provide protection from flying snow and

debris. Allow even more distance when driving on slippery surfaces

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

aware of any snowmobile traffic around your vehicle. Drive defen-

sively to avoid accidents.

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

unattended.

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SAFETY

Operator Safety

Windchill/Temperature Charts

The following information is provided to help you determine when tem-

peratures become dangerous for riding.

WINDCHILL CHART (°F)

Wind

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 instruc-

tions of the labels on the snowmobile.

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

dealer to purchase a replacement. Replacement safety labels are pro-

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

label.

Clutch Warning

This warning label is found on the oil bottle:

WARNING

Do not operate engine with hood or side panels open.

Do not attempt adjustment with engine running.

Do not operate engine with the clutch guard removed.

Never run engine with drive belt removed.

Never service clutches yourself. See your dealer.

Pressure Cap Warning

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

cooled models:

WARNING

Do not open hot. Test or replace when changing coolant. Press

down and turn to release cap. 13 PSI

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SAFETY

Safety Labels and Locations

Track Warning

Track

Warning

WARNING

Stay clear of track. Do not

sit on seat back. Entangle-

ment with the track or a fall

from seat back may result

in severe injury or death.

No Passenger Warning/Fuel Recommendation Label

WARNING

This vehicle is designed for operator only. NO PASSENGER.

Reverse Warning

No Passenger Warning/Fuel

Recommendation Label

WARNING

Reverse operation, even at low

speeds, can cause loss of control

resulting in serious injury or

death. To avoid loss of control,

always:

• Look behind before and while

backing up.

• Avoid sharp turns.

• Shift to or from reverse only

when stopped.

• Apply throttle slowly.

NOTE: For more information, see

Owner's Manual.

If electric reverse:

Reverse Warning

• 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

Operation Warning

WARNING

• To avoid serious injury or death,

read and understand all warn-

ings 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 unfa-

miliar terrain.

Operation

Warning

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

result in insufficient time for you to react to terrain changes, to

avoid unexpected obstacles, or to stop safely.

• Never consume alcohol or drugs before or while operating this vehi-

cle.

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

on the top of the throttle control assembly, to stop the engine. Then

pull the brake lever to stop.

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

clothing while operating this vehicle.

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

requirements.

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

reduce speed and allow extra space for steering and stopping. A

passenger reduces your ability to control the vehicle.

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

steering and braking ability are greatly reduced. Reduce speed and

allow extra space to turn or stop.

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

should have a proper balance of ski carbides to track studs. See

Owner's Manual for proper use of traction products.

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

of braking ability.

• Parking brake may relax when used for long periods. 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

9. Taillight

10. Rear Bumper

11. Snow Flap

12. Suspension

13. Track

5. Headlight

6. Windshield (accessory)

7. Handlebar

8. Operator Seat

14. Side Panel

15. Side Panel Fasteners

16. Tool Kit/Storage Bag

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FEATURES

1. Brake Lever

2. MFD Gauge

3. Ignition Switch

4. Engine Stop Switch

5. Throttle Control

6. Recoil Starter Handle

7. Parking Brake Lock

8. Handlebar Grip Warmer Switch

9. Thumbwarmer Switch

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-

ward.

Down

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FEATURES

Fuel Type Selection

Whenever using ethanol, MTBE or other forms of oxygenated gaso-

lines, 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.

1. Start the engine.

2. Lock the parking brake.

3. Press and release the

SELECT button or SET

switch until “FUEL” is dis-

played 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 temporary and the operator does not

need to take any action. The engine

will return to its normal performance

automatically.

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.

Check Engine Light

Indicates

Solid or Flickering

Steady Flashing

Excessive detonation detected

Severe detonation detected, RPM will be limited

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FEATURES

Detonation Elimination Technology (DET)

The most likely causes of severe detonation are outlined in the trouble-

shooting table below.

DET Troubleshooting

Cause of DET Activation

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

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 37 of the Instrument Cluster

section for security system activation and operating instructions.

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FEATURES

Instrument Cluster

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 infor-

mation center. The information cen-

ter can be controlled by either the

MODE and SELECT buttons on the

instrument cluster or by the MODE/

SET switch on the left handlebar.

NOTICE: Certain products will damage

the lens and other plastic sur-

faces. Do not use alcohol to

clean the instrument cluster.

Immediately clean off any

Mode/Set

Switch

gasoline that splashes on the

instrument cluster.

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FEATURES

Instrument Cluster

Indicators

Check Engine Indicator

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

snowmobile if this warning appears. Serious engine damage could

result. See your dealer. See page 44 for diagnostic code definitions.

Over-Temperature Indicator

This indicator illuminates to alert the operator that the engine is over-

heating. The operator should take action to cool the engine. See page 92.

If the indicator flashes, continued operation could result in serious

engine damage. Stop the engine immediately.

Low Oil Indicator

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

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

mended oil before further operation. See page 73.

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 64.

Reverse Indicator

This indicator flashes when the snowmobile is in reverse. See page 78.

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FEATURES

Instrument Cluster

Rider Information Center

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

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

meters (2), total engine hours of operation, fuel level, engine tempera-

ture and diagnostic display mode.

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

cle powered by an external DC power supply connector.

The information center is set to display standard units of measurement

for distance and temperature. To change to metric units, see page 36.

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FEATURES

Instrument Cluster

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 dis-

play, see page 34.

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

speed or engine speed. To change the display, see page 34.

3. Fuel Gauge - The segments of the fuel gauge show the level of fuel

in the fuel tank. When the last segment clears, a low fuel warning is

activated. All segments including the fuel icon will flash. Refuel

immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the

fuel sensor circuit. See your dealer.

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

Trip A, Trip B and engine hours. To change the display, see page 35.

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

low.

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

and play back engine speed, vehicle speed and throttle position sen-

sor information for up to three minutes. The playback icon flashes

while recording. See page 35.

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FEATURES

Instrument Cluster

Rider Information Center

Speed Display Area

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

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

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

(RPM).

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

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

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

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

Information Display Area

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

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

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

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

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FEATURES

Instrument Cluster

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 vehi-

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

displays the total hours the engine has been in operation since manufac-

ture.

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

switch until the desired item is displayed.

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

switch until the meter resets to zero.

Playback Function

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

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

three minutes.

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

SELECT buttons on the instrument cluster for three seconds. The

playback indicator will flash while the instrument cluster is record-

ing.

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

speed to drop below clutch engagement.

3. Simultaneously press and release the MODE and SELECT buttons

on the instrument cluster.

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

cluster to normal operation.

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FEATURES

Instrument Cluster

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

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 snow-

mobile 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 secu-

rity code to one of your own choosing.

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FEATURES

Instrument Cluster

Rider Information Center

Security System (Ignition Lock System)

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

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

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 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 alter-

nate 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

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

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 Secu-

rity System procedure beginning on page 38. Instead of using the fac-

tory 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

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 fol-

lowing 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 but-

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

code. Repeat until all codes are retrieved.

5. See page 44 for code definitions and failure descriptions.

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FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions

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

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

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

control unit and the item listed in the chart.

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

shorted together, or the item has shorted internally.

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

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

Diagnostic Codes

Component

Throttle Position Sensor

Condition

Voltage Too High

SPN

FMI

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

Voltage Too Low

Voltage Too High

108

110

Voltage Too Low

Temperature Too High

Engine Overheat Shutdown

Temperature Above Normal Range

Voltage Too High

Voltage Too Low

Voltage Too High

Alternator Power Supply

167

173

Potential (DC Chassis Voltage)

Exhaust Temperature Sensor

Voltage Too Low

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FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions

Diagnostic Codes

Component

ECU Memory

Condition

Checksum/CRC Error

SPN

628

651

FMI

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

Fuel Pump Driver Circuit

Knock Level Cylinder 1 (MAG)

Driver Circuit Open/Grounded

Maximum Detonation Correction

Limit Reached

1347

1352

Knock Above Critical Level

Maximum Detonation Correction

Limit Reached

Knock Level Cylinder 2 (PTO)

1353

Knock Above Critical Level

Voltage Too Low

Sensor Supply Voltage 1 (TPS/

TMAP Sensor Power)

Sensor Supply Voltage 2

(Ground Speed Sensor)

ECU Output Supply Voltage 2

(Injection Supply PWR)

3509

3510

3598

Voltage Too Low

Voltage Too High

Voltage Too Low

Voltage Too High

Voltage Too Low

Throttle Release Signal

520194

Throttle Stuck

Chassis Relay

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Driver Circuit Short to B+

520208

520215

520216

Exhaust Valve Solenoid

Injector 1 (MAG) (Case Injector) Driver Circuit Open/Grounded

Driver Circuit Short to B+

Driver Circuit Grounded

Injector 2 (PTO) (Case Injector) Driver Circuit Open/Grounded

Driver Circuit Short to B+

520217

524007

Driver Circuit Grounded

Fuel Type Selected

Voltage Too High

Voltage Too Low

Signal Out Of Range

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THE PERFECT FIT

Suspension Quick Set-Up Guide

The suspension on your RUSH is incredibly easy to adjust to your

weight and riding style. Just remember three simple steps:

1. Set up rear shock spring preload for rider weight.

2. Adjust the rear spring to tune vehicle balance (ski pressure and

weight transfer).

3. Adjust shock clickers to tune ride quality (stiffer or softer ride).

The following Quick Set-Up Guide walks you through what you need to

know to get started, and additional detail is available on the pages

immediately following the guide. See pages 48-49 for factory and initial

suspension charts for the standard spring as well as for accessory

springs that are available for heavier or lighter riders.

Step 1: Set up rear shock spring preload for rider weight.

Before riding for the first time, use the gauge supplied with your snow-

mobile to adjust rear spring preload to the appropriate setting for the

rider’s weight.

Position the narrow end of

the gauge flush with the

spring retainer. Turn the

spring until the rider’s

weight setting aligns with

the junction of the shock

body and end cap.

Spring Retainer/Adjustment Nut

Make no other suspension

adjustments at this time.

Test ride the snowmobile in

various terrain to fully expe-

rience the existing suspen-

sion settings before making

adjustments.

Shock Body/End Cap

Junction

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THE PERFECT FIT

Suspension Quick Set-Up Guide

Step 2: Adjust the rear spring to tune vehicle balance.

After the initial test ride, make adjustments to the rear shock spring to

improve vehicle balance. Increasing preload will increase ski pressure

and result in less weight transfer, flatter cornering and more precise

steering response. Decreasing preload will decrease ski pressure and

result in more weight transfer, or less weight on the skis when accelerat-

ing.

Ride Experience

Too much weight transfer

•Ski pressure is too light

•Skis push

Adjustment

Turn rear shock spring

retainer clockwise (see

page 55)

Too little weight transfer

•Ski pressure is too heavy

•Steering is heavy

Turn rear shock spring

retainer counter-clockwise

(see page 55)

Step 3: Adjust shock clickers for ride quality.

After making spring adjustments, adjust shock clickers to control bot-

toming. Turning a clicker counter-clockwise decreases damping for a

softer ride. Turning a clicker clockwise increases damping for a stiffer

ride and less bottoming.

NOTICE: Always adjust the clicker at least one click below full stiff (full clock-

wise) or shock damage will occur.

Test ride the snowmobile and continue making spring and clicker

adjustments until you achieve the perfect ride.

TIP:Initially, heavier riders may want to set the shock clickers 2-4 clicks higher

than lighter riders.

Clicker

See

Ride Experience

Adjustment

Clockwise

to Adjust

Page

Bottoming in the IFS

IFS shock - after

150 mi. (240 km)

break-in

Bottoming in the center

Bottoming in the rear

Front track shock

Rear shock

Clockwise

No bottoming, but ride is IFS shock (after

Counter-clockwise

harsh in front or rear

break-in), Front

track shock, Rear

shock

Harsh in chatter/bumps

Front track shock,

Rear shock

Counter-clockwise

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THE PERFECT FIT

Suspension Quick Set-Up Guide

Accessory rear shock springs are available for riders of different

weights. A corresponding gauge is available for each spring type.

The gauge provided with your snowmobile is calibrated for the stock

spring, which should be used by most riders. Do not change springs

unless your weight is at the very high or very low end of the stock spring

rider weight range and adjustments to the factory-installed spring have

not perfected your ride.

In the following spring guide, the dimension is as measured from the

spring retainer to the junction of the shock body and end cap. See page

46.

Spring Guide

Accessory

120 Spring

Accessory

260 Spring

Stock Spring

See your POLARIS dealer to order an accessory

spring and the gauge calibrated for that spring.

Rider

Weight

lbs. kg

120 54

130 59

140 64

150 68

160 73

170 77

180 82

190 86

Dimension

in.

Weight

Dimension

in.

41 2.375 6.03 240 109 2.125 5.40

43 2.5 6.35 255 116 2.25 5.72

Weight

Dimension

cm lbs. kg

in. cm

1.5 3.81 90

Min

100 45 2.625 6.67 270 122 2.375 6.03

105 48 2.75 6.99 280 127 2.5 6.35

50 2.875 7.3 295 134 2.625 6.67

52 7.62 310 141 2.75 6.99

1.75 4.44

2.0 5.08

2.125 5.39

110

115

120 54 3.125 7.94 320 145 2.875 7.3

125 57 3.25 8.26 335 152

Max

7.62

200 91

210 95

220 100

230 104

240 109

130 59 3.375 8.57

135 61 3.5 8.89

140 64 3.625 9.21

150 68 3.75 9.53

2.25 5.71

2.50 6.35

155 70 3.875 9.84

Max

2.75 6.98

Max

260 118

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THE PERFECT FIT

Suspension Quick Set-Up Guide

Factory Suspension Settings

IFS and Front Track Shock

IFS Shock Clicker

6 clicks clockwise from full soft

IFS Shock Spring Preload

From body end to spring:

FOX shocks 3.75 inches (9.52 cm)

PRO-R shocks 3.00 inches (7.62 cm)

800 LE shocks 3.00 inches (7.62 cm)

Rebound Clicker (800 LE)

Front Track Shock Clicker

8 clicks clockwise from full soft

2 clicks clockwise from full soft

Front Track Shock Spring Preload 2 inches (5 cm) from body end to spring

Stock Rear Spring

Rear Shock Clicker

4 clicks clockwise from full soft

Rear Shock Spring Preload

See Optional Spring Guide (page 48)

Accessory Spring Recommended Initial Settings

Accessory 120 Rear Spring

Rear Shock Clicker

4 clicks clockwise from full soft

Rear Shock Spring Preload

See Optional Spring Guide (page 48)

Accessory 260 Rear Spring

Rear Shock Clicker

4 clicks clockwise from full soft

Rear Shock Spring Preload

See Optional Spring Guide (page 48)

POLARIS recommends that riders use this Quick Set-Up Guide to make

any adjustments for rider weight and trail conditions. If additional tun-

ing is needed after you have exhausted all possible adjustments to the

rear shock spring and clicker, refer to the information on the following

pages of this manual.

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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 experi-

ence 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 condi-

tions, 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

• Compression damping

• Optional springs

• Optional shock valving

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Front Suspension Adjustments

IFS Shock Spring Preload

Increasing spring preload will increase ski-

to-ground pressure. Decreasing spring pre-

load 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.

Always perform shock spring preload

adjustments with the weight of the vehicle

removed from the shock and with the shock

at full extension.

To change shock spring preload, grasp the

spring retainer and rotate it.

Initial IFS Preload Setting

(from body end to spring)

FOX shocks

3.75 inches

(9.5 cm)

Pro-R premium shocks

800 LE shocks

3.00 inches

(7.6 cm)

Measure

here

3.00 inches

(7.6 cm)

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.

TIP:Other spring options are available. Please see your POLARIS dealer.

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THE PERFECT FIT

Front Suspension Adjustments

IFS Shock Compression Damping

Make adjustments to the shock clickers to control bottoming. Make the

adjustments in 1-to-2-click increments, then test ride. Repeat the adjust-

ment until the desired result is achieved.

TIP:Initially, heavier riders may want to set the shock clickers 2-4 clicks higher

than lighter riders.

The standard clicker setting is 6 clicks from

the softest position.

Stiffer

Ride

Softer

Ride

• Turn the clicker clockwise for a stiffer ride

(as viewed from the top).

• Turn the clicker counter-clockwise for a

softer ride.

When adjusting, we recommend that you turn

the clicker only one or two clicks, then test

ride. Always adjust both shocks equally.

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.

Rebound Clicker (800 LE)

The rebound adjustment clicker is located on the bottom end of the

shock. This adjuster has 16 possible adjustments. The factory setting is

8 clicks clockwise from full soft.

When adjusting, turn the clicker two clicks, then test ride. Always adjust

both shocks equally. Repeat the adjustment until the desired result is

achieved.

• Turn the clicker clockwise to slow rebound control (shock extends

slower).

• Turn the clicker counter-clockwise to increase rebound control (shock

extends faster).

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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 sus-

pension designs and adjustments involve a compromise, or trade-off.

For example, a suspension set up for snowcross racing would provide a

very stiff ride on the trail. A suspension set up for trail riding would bot-

tom out harshly on a snowcross course.

Additional adjustments should be made after initial setup. Make adjust-

ments to one area at a time so you can evaluate the change. For further

assistance, see your dealer.

Suspension Performance Tips

• Rider weight usually determines the position at which the spring pre-

load should be set. However, this may vary with riding style. With a

little experimentation, each rider can find a preferred set-up.

• 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 snowmobile's performance. Bogie wheel

kits are available from your dealer.

Track Tension

Track adjustment is critical for proper handling. Always maintain cor-

rect tension and alignment. Refer to the track tension maintenance sec-

tion beginning on page 106.

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THE PERFECT FIT

Rear Suspension Adjustments

Front Track Shock Compression Damping

Make adjustments to the shock

clicker to control bottoming. Make

the adjustments in 2-click incre-

ments, then test ride. Repeat the

adjustment until the desired result is

achieved.

Stiffer

Softer

TIP:Initially, heavier riders may want to

set the shock clickers 2-4 clicks

higher than lighter riders.

The standard clicker setting is 2

clicks from the softest position.

• Turn the clicker clockwise for a stiffer ride.

• Turn the clicker counter-clockwise for a softer ride.

Front Track Shock Spring Preload

Always perform shock spring preload adjustments with the weight of

the vehicle removed from the shock and with the shock at full extension.

Increasing spring preload will decrease ski-to-

ground pressure. Decreasing spring preload will

increase ski-to-ground pressure.

The initial preload setting is 2 inches (5 cm) from

body end to spring. To change shock spring pre-

load, grasp the spring retainer and rotate it.

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.

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.

TIP:Other spring options are available. Please see your POLARIS dealer.

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THE PERFECT FIT

Rear Suspension Adjustments

Rear Shock Spring Preload Settings

Make adjustments to the rear shock spring to tune vehicle balance.

Always perform shock spring preload adjustments with the weight of

the vehicle removed from the shock and with the shock at full extension.

Increasing preload will increase ski pressure and result in less weight

transfer and flatter cornering and more precise steering response.

Decreasing preload will decrease ski pressure and result in more weight

transfer, or less weight on the skis when accelerating.

Turn the spring retainer up to one turn from the initial setting, then test

ride. Repeat the adjustment in one-turn increments until the desired

result is achieved.

Increasing the spring preload too much may adversely affect the han-

dling of the snowmobile and the performance of the suspension. Never

exceed one inch (2.54 cm) of preload beyond the factory settings.

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.

Rear Shock Clicker

Make adjustments to the shock

clicker to control bottoming, chatter

and general riding comfort. Make

the adjustments in 2-click incre-

ments, then test ride. Repeat the

adjustment until the desired result is

achieved.

TIP:Initially, heavier riders may want to

Softer

set the shock clickers 2-4 clicks

higher than lighter riders.

Stiffer

The standard clicker setting is 4

clicks from the softest position.

• Turn the clicker clockwise for a stiffer ride.

• Turn the clicker counter-clockwise for a softer ride.

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THE PERFECT FIT

Handlebar Adjustments

Handlebar Position

1. Loosen the four bolts on

the bottom of the adjuster

block. If necessary, pry the

blocks apart with a screw-

driver.

Loosen top bolts to adjust

handlebar angle

2. Adjust the handlebar for-

ward or rearward to the

desired position.

3. Tighten the bolts. Torque

the bolts to 13-16 ft. lbs.

(18-22 Nm).

Handlebar Angle

1. Loosen the four bolts on

the top of the adjuster

block. If necessary, pry the

blocks apart with a screw-

driver.

Loosen bottom bolts to

adjust handlebar position

2. Adjust the handlebar for-

ward or rearward to the

desired 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, loosen the set

screws for the left and right controls, rotate the controls slightly,

then tighten the set screws to the proper torque.

NOTICE: Do not stretch wires while adjusting the controls. Stretching the wires

could damage the handwarmers.

• Right control torque: 27 in. lbs. (3.05 Nm) +/- 10%.

• Left control torque: 24 in. lbs. (2.7 Nm) +/- 10%.

3. Tighten the bolts. Torque the bolts to 13-16 ft. lbs. (18-22 Nm).

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THE PERFECT FIT

Accessories

POLARIS offers a wide range of accessories for your snowmobile to

help make each ride more enjoyable.

Use only POLARIS parts and accessories on your POLARIS snowmo-

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

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others

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

fuel systems, internal engine components 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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THE PERFECT FIT

Traction Products

Studs

The track is not warranted by POLARIS if studs have been installed.

Track warranties are also void if track damage or failure results from the

use of any non-POLARIS traction products. Use only POLARIS-

approved traction products on your snowmobile.

If you choose to install studs, stud length must not exceed 1.45 inches

(37 mm) for a factory-installed track.

See your dealer about installing studs and/or carbides.

NOTICE: Always install wear strips before installing studs. Failure to install wear

strips may result in cooler or tunnel damage. See page 59.

Never add shims to the wear strip. Track damage will result because

of lack of clearance between upper carrier wheels and track.

Use of studs longer than the recommended length on snowmobiles

equipped with center coolers will result in center cooler damage or

damage to the tunnel.

Track studding will enhance braking control on hard-packed snow or

ice, but extreme caution is still required on such surfaces. Steering abil-

ity may be reduced on hard-packed snow or ice.

When studded tracks are used, increased wear to the brake pads will

result from increased braking. Extended-wear brake pad kits are avail-

able. See your dealer.

NOTICE: Aggressive studding patterns may require grinding protruding stud

bolts flush to prevent idler wheel damage. Maintain track tension on

studded tracks on the tight side of the spec to prevent heat exchanger

damage. The center of the stud must be at least 1 1/8 inch (2.9 cm)

from the outside edge of the track.

Before equipping your snowmobile with traction products, be aware of

the laws in your area pertaining to the use of traction products.

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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 111.

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.

Wear Strips

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

whenever track studding is used. Wear strips are designed for a specific

stud length.

See your dealer's studding chart for recommended traction accesso-

ries.

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

clearance to the heat exchangers. Lack of clearance may result in

damage to heat exchangers.

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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 refer-

enced pages.

Item

See Page

Drive Belt Condition

Steering System

Recoil Rope

101

Coolant Level

Chaincase Oil Level

Injection Oil Level

Parking Brake Lock/Brake Lever/Brake System

Auxiliary Shut-Off Switch (Engine Stop Switch)

Ignition Switch

63, 64, 96

Headlight/Taillight/Brakelight

Suspension Mounting Bolts

Skags (Wear Bars)

111

Ski Saddle and Spindle Bolts

Hood and Side Panel Fasteners

Throttle Lever/Safety Switch

Rear Wheel Idler Bolts

74, 75

107

Tether Switch/Strap (if equipped)

Track Alignment/Condition

Rail Slide Condition

65, 108

112

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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 follow-

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

Item

See Page

Check suspension mounting bolts for tightness.

Check rear idler wheel bolts for tightness.

Check rear idler adjusting bolt locknuts for tightness.

Check front torque arm limiter strap condition.

Check rail slide condition.

See Dealer

107

112

106

111

109

Check track tension.

Check ski runner/skag condition.

Check ski spindle bolts for tightness.

Check tie rod end nuts for tightness.

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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 func-

tion smoothly, or if you discover excessive lever freeplay, DO NOT start

the engine. Have the throttle serviced immediately.

Throttle Safety Switch

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

See page 74.

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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” (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 98 or

see your dealer for service.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid

level and condition. Add fluid as needed. See page 97.

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; for example, 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 will illuminate if the parking brake lever lock is

set while the engine is running. It will also illuminate when the service

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

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

Lock Release

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

to the unlocked position.

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.

Side Panel Fasteners

The side panels of the snowmobile protect the operator from moving

parts. Never operate the snowmobile with the side panels open or

removed.

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 62.

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 snowmobile 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 (6 mm) 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 draw fresh air through 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: POLARIS VES 2-Cycle Oil

After Break-in:

POLARIS VES 2-Cycle Oil

See page 115 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-fit-

ting machined parts, allowing them to break in slowly without damage.

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

may cause serious engine damage. We recommend the use of

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 snow-

mobile.

Oil Injection System

Always check and fill the oil bottle when refueling. See page 73.

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

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

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

Drive Belt Break-In

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

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

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

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

ing throttle.

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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 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. Never rotate a dry track. For best track performance, always lubri-

cate the track with water or snow before rotating the track.

2. Use an appropriate stand to securely support the rear of the snow-

mobile at the rear bumper. The track should be about 4 inches (10

cm) off the ground.

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

4. 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.

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

the snowmobile to the ground.

6. 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 refu-

eling 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 can-

cer, 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. 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 115 for the part numbers of POLARIS prod-

ucts.

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

ated”) do not add deicers or additives that contain any form of alcohol.

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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

68 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 refu-

eling. Add oil as needed.

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

dealer for recommended replacement parts.

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OPERATION

Engine Stop Switch

Push down on the engine

stop switch (X) to ground

out the ignition and stop

the engine quickly. Pull

the switch up to the ON

position to allow restart-

ing.

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 pres-

sure on the pivot pin in the direction shown in the illustration.

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

must shut down the engine.

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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

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the

event of an emergency. See page 74 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

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 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 snowmobile is in reverse. Never

engage the starter when the engine is running.

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OPERATION

Electronic Reverse (PERC)

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

ond, then release. The engine will automatically reduce RPM and

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

panel will indicate that the snowmobile is in reverse.

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

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

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

restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

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

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

engage the starter when the engine is running.

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

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

ment panel will shut off.

3. Apply the throttle slowly to make sure the snowmobile is in for-

ward.

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OPERATION

Daily Storage

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

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

suspended approximately 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 con-

trol information (ECI) label and a factory-installed emissions informa-

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

Protection Agency regulations. The ECI label is permanently affixed to

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

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

You may remove the factory-installed emissions information hangtag,

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

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum

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

check engine light and it comes on, you must take your snowmobile to a

qualified dealer for diagnostic service. Specifications and adjustments

for engine tune-ups are located in the Service Manual, which is avail-

able to your qualified service technician. Reverse (if equipped) must not

be engaged during engine tune-ups.

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty, and

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

ble for ensuring that the specified maintenance is performed. POLARIS

recommends that you contact an authorized POLARIS dealer to perform

any service that may be necessary.

Non-ionizing Radiation

This vehicle emits some electromagnetic energy. People with active or

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

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

applicable electromagnetic standards and directives that apply to this

vehicle.

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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 out-

lined in this manual. Record maintenance and service in the Mainte-

nance Log beginning on page 133.

The recommended maintenance schedule on your snowmobile calls for

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

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

formed by a qualified service technician. For continued optimum perfor-

mance and component life, continue maintenance checks at 1000 mile

(1600 km) intervals.

All necessary replacement parts and labor incurred, with the exception

of authorized warranty repairs, become the responsibility of the regis-

tered owner. If, during the course of the warranty period, part failures

occur as a result of owner neglect in performing recommended regular

maintenance, the cost of repairs are the responsibility of the owner.

Personal safety is critical when attempting to service or make adjust-

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

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

able performing these tasks yourself, contact an authorized POLARIS

dealer for service.

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

exhaust system and engine have cooled before tipping the snowmo-

bile on its side for service or inspection.

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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)

100

Drive Belt Condition

Clutches

101

100

Belt Tension

Clutch Sheaves

100

ENGINE/COOLING

Engine Mounts

Recoil Rope

Cylinder Head Bolts

Cylinder Base Nuts

Ignition Timing BTDC

VES System

Coolant Level

Coolant Hose

Coolant Circulation

Coolant Leaks

Spark Plugs

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

Brake Disc

Parking Brakes

Brake System

Brake Fluid

63, 96

FUEL MANAGEMENT

Idle RPM

Throttle Lever

Oil Pump Lever

(synchronize)

Throttle Position Sensor

Fuel Lines

Fuel Filter Replacement

Oil Filter

EVERY 2000 (3200) or EVERY 2 YEARS

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

1000 mi.

150 mi.

500 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

Steering Fasteners

Rear Suspension

Fasteners

Rear Suspension

Bushings

112

Suspension Shock Oil

Rear Shock Threads

Cooling Fins and

Shroud

Skags (Wear Bars)

111

Ski Saddle/Spindle Bolts

Drive Chain Tension

Hood and Side Panel

Fasteners

Rear Wheel Idler Bolts

Idler Bolt Jam Nut

107

112

Rear Suspension Pivot

Shaft

Camber Alignment

Handlebar Centering

Tether Switch and Strap

Track Tension

106

108

Track Alignment

Front Limiter Strap

Rail Slide Condition

Chaincase Oil

112

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

C - Clean R - Replace L - Lubricate

Bolt Torque Inspection

To maintain proper chassis performance, see your POLARIS dealer for

a bolt torque inspection every 1000 miles (1600 km).

Item

Description

Engine Mounting Bolts

Chaincase Mounting Bolts

Remove drive clutch and resonator for access to all bolts

Two (2) TORX-head bolts on forward side of chaincase

Four (4) rear chaincase nuts

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MAINTENANCE

Hood/Side Panel

The hood and side panels of the

snowmobile protect the operator

from moving parts. Never oper-

ate a snowmobile with the side

panels open or removed.

Strap

Always ensure that the hood

and side panels are securely in

place before starting the engine.

To open a side panel, rotate the

two 1/4-turn fasteners at the

upper edges of the side panel.

Release the side panel strap at

the lower edge of the panel.

1/4-Turn Fasteners

To remove an open side panel,

pull the panel outward to release

the tabs at the lower edge of the

panel.

Removing the hood is not recommended. Any service requiring the

removal of the hood should be performed by an authorized POLARIS

dealer.

Lubrication

Rear Shock Body Threads

Lubricate rear shock body threads

seasonally with a low-temperature

synthetic grease.

Threads

Driveshaft Bearing

This model has sealed bearings that

require no additional lubrication.

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MAINTENANCE

Lubrication

Chaincase Oil

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

tenance charts beginning on page 81. Maintain the oil level at the top of

the fill plug hole. POLARIS recommends the use of POLARIS Syn-

thetic Chaincase Lube. See page 115 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 to

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 to 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 to 6-10 ft. lbs. (8-13 Nm).

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MAINTENANCE

Intake Filters

The intake foam filters limit

snow ingestion into the intake

system. When operating in loose

powder snow, check the foam

filters periodically to remove

any accumulation of snow.

Foam Filters

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 inter-

vals outlined in the Periodic Maintenance Table beginning on page 81.

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

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

containers. If low fuel pressure or reduced engine performance occurs

between the recommended fuel filter service intervals, the filter may

need replacement. See your dealer.

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

Always check fuel line condition after periods of storage. Normal dete-

rioration from weather and fuel compounds may occur. Replace worn or

damaged fuel lines promptly.

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

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

or kinked, replace it promptly.

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MAINTENANCE

Spark Plugs

Spark Plug Recommendations

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

vative added during the assembly process. Avoid prolonged idle speeds,

which cause plug fouling and carbonization.

Change the spark plugs at the intervals outlined in the Periodic Mainte-

nance Table beginning on page 81. Refer to the specifications section

for the specific spark plug to be used in your snowmobile.

• 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. Refer to the specifications section beginning on

the page 116.

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MAINTENANCE

Spark Plugs

Spark Plug Inspection

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

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

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

spark plug for correct color.

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

protective gloves when removing a spark plug for inspection.

1. Remove the left side panel.

2. Remove the spark plug cap.

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

spark plug counter-clockwise to remove.

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

cation.

5. Reinstall the spark plug cap.

Spark Plug Condition

Normal Plug

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

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

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

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

Oil Lines

Inspect oil line condition every 1000 miles (1600 km).

Oil Filter

Please see your dealer for replacement of the in-line oil filter every 2000

miles (3200 km) as outlined in the maintenance charts beginning on

page 81.

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MAINTENANCE

Cooling System

Coolant

The coolant supplied in the system at the factory is a 50/50 mixture of

ethylene-glycol and distilled water, which will provide adequate freeze

protection under most conditions. If the vehicle will be stored or oper-

ated at extremely low temperatures, greater protection may be required.

Please see your POLARIS dealer.

When adding or changing coolant, POLARIS recommends using

POLARIS Antifreeze 60/40 Premix. POLARIS Antifreeze is already

premixed and ready to use. Do not dilute with water. Never exceed a

60% antifreeze/40% water mixture. See page 115 for POLARIS prod-

ucts.

Never add tap water to the cooling system. Minerals cause deposits and

may react adversely with the metals in the engine and cooling system.

Coolant Level

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

recovery system components are:

• Coolant bottle/overflow tank

• Pressure cap

• Connecting hoses

Always maintain the coolant level at or

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 over-

heating and serious engine damage. Always maintain the coolant

level as recommended.

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MAINTENANCE

Cooling System

Engine Overheating

The over-temperature indicator on the

instrument cluster will illuminate when the

engine is overheating. The indicator will

flash when engine temperature reaches

critical levels.

Illuminated Indicator

Take action to cool the engine:

• Drive in loose snow.

• View the coolant level. Do not open the

pressure cap while the engine is hot.

Add coolant if the level is low.

• Stop the engine and allow it to cool down.

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

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

Flashing Indicator

If the indicator flashes, continued operation could result in serious

engine damage. The system will automatically reduce engine power and

create a misfire condition. Stop the engine immediately. Allow the

engine to cool down.

If engine overheating seems to be caused by something other than poor

cooling conditions, see your dealer for service.

Flushing the Cooling System

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

drain the system completely every two years and add a fresh mixture of

antifreeze and distilled water. This service must be performed when the

engine is cold. Ask your POLARIS dealer to check the coolant when he

performs the fall tune-up on your snowmobile.

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MAINTENANCE

Cooling System

Bleeding the Cooling System

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

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

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

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

dealer for the correct part.

NOTICE: Severe engine damage may occur if the cooling system becomes

restricted or plugged or contains trapped air pockets.

Peform this procedure in a well-ventilated area. Use the recommended

coolant. See page 91.

1. Open the side panels and remove the hood.

2. Close the side panels.

WARNING! Never operate a snowmobile with the side panels open or removed.

3. Position the vehicle with the right ski and control arms elevated at a

45-degree angle.

4. Fill the coolant bottle to the COLD FILL mark.

5. Using an 8mm wrench, loosen the air bleed screw located on the top

of the coolant outlet elbow. Use a shop towel to catch any coolant

that leaks from the bleeder. Tighten the screw after a steady stream

of coolant flows from the bleeder.

6. Fill the coolant bottle to the COLD FILL mark.

7. Install the coolant bottle cap to the first lock. Do not tighten to the

fully seated position.

8. Lock the parking brake.

9. Start the engine and run at a fast idle for several minutes, until the

heaters are warm to the touch. Loosen the bleed screw occasionally

to purge any trapped air.

10. When all heater extrusions are warm to the touch, stop the engine.

11. Allow the engine and cooling system to cool.

12. Fill the coolant bottle to the COLD FILL mark.

13. Carefully lower the front end of the snowmobile.

14. Secure the bleed screw and reinstall the pressure cap.

15. Open the side panels and reinstall the hood. Close the side panels.

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MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at approximately 2000

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

completely before inspecting.

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

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

running.

1. Open the side panels and remove the hood. See page 85.

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.

5. Reinstall the hood and side panels.

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MAINTENANCE

Drive Chain Tension

Check drive chain tension at the intervals outlined in the maintenance

charts beginning on page 81 and before each long trip.

1. Remove the side panels.

2. Rotate the driven clutch coun-

ter-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 to 21 ft. lbs. (28 Nm).

6. Reinstall the side panels.

7. Release the brake lever lock.

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MAINTENANCE

Brakes

Hydraulic Brake Inspection

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

page 63.

Brake pads must be replaced when the brake pad material becomes thin-

ner 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/1.5

mm).

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.

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MAINTENANCE

Brakes

Brake Fluid

The brake fluid level can be seen through a plastic sight glass in the

brake reservoir. If the fluid is sufficient, the sight glass will be black. If

the sight glass is any color other than black, add brake fluid.

Replace brake fluid at least every two years with POLARIS DOT 4 high

temperature brake fluid. See page 115 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.

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MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

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

Bleed the system before operating the snowmobile.

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

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

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

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

ble. The reservoir must be in this position to minimize the possibility of

air entering the system through the reservoir vent.

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

2. 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 97.

8. Reinstall the gasket and cover.

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MAINTENANCE

Lights

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

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

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

denatured alcohol.

Headlight Lamp Replacement

1. Remove the wire harness connector from the back of the headlight.

2. Grasp the bulb housing and turn it counter-clockwise to remove the

bulb.

3. Apply dielectric grease to the socket and install the new bulb.

Rotate the bulb 1/4 turn clockwise to secure it.

4. Reinstall the connector to the back of the headlight.

Taillight/Brake Light Replacement

The taillight assembly is not serviceable. If the light fails to operate

properly, replace the entire taillight assembly.

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MAINTENANCE

Clutch System

Periodically inspect clutch sheaves for damage, wear or belt residue. To

maintain optimum performance, clean with non-oil based cleaners such

as isopropyl alcohol.

WARNING! If you become aware of higher than normal clutch engagement or

an unusual vibration or shift pattern, see your dealer immediately. Do not

operate the 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 perfor-

mance. See your dealer for service and adjustments. A special tool is

required to check for proper alignment.

100

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MAINTENANCE

Clutch System

Drive Belt Condition

Periodically check the condition and tension of the drive belt. Inspect

the belt for signs of excessive wear: frayed edges, missing cogs, cracks

and excessive looseness. Replace the belt if any of these conditions

exist. See Drive Belt Troubleshooting on page 124.

Always carry a spare drive

belt. Store the spare belt in

the belt clip located under

the left side of the hood.

O-Ring

Make sure the o-ring is

installed over the belt clip.

For improved drive-away during extremely cold temperatures, remove

the belt and warm it to room temperature. Reinstall it before starting the

snowmobile.

101

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MAINTENANCE

Clutch System

Drive Belt Deflection

Measure belt deflection with both

clutches at rest and in their full

neutral position.

Place a straight edge (1) on the

belt and apply downward pressure

while measuring at point 2. This

measurement should be 1 1/4

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 (clock-

wise) to increase the distance between the sheaves or outward

(counter-clockwise) to decrease the distance.

3. Tighten the jam nut.

102

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MAINTENANCE

Clutch System

Drive Belt Removal

NOTICE: Do not attempt to remove the drive belt after operating in reverse. The

snowmobile must be stopped after forward motion to prevent damage

to components during belt removal. Rotate the driven clutch counter-

clockwise 1/4 turn by hand to ensure forward engagement before

attempting to remove the belt.

1. Stop the engine after operating in a forward motion.

2. Turn the ignition key off. Wait for the engine to come to a complete

stop.

3. Lock the parking brake.

4. Remove the left side panel.

5. Rotate the driven clutch counter-clockwise 1/4 turn by hand to

ensure forward engagement.

6. Locate the L-wrench in the tool kit. Install the wrench into the open

threaded hole in the outer sheave of the clutch.

7. Turn the wrench clockwise until the sheaves open far enough to

remove the belt. If the wrench does not turn readily, rotate the

driven clutch counter-clockwise an additional 1/4 turn by hand and

try again.

8. Firmly grasp the belt midway between the clutches and pull upward

and rearward to remove it.

103

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MAINTENANCE

Clutch System

Drive Belt Installation

1. Drop the drive belt over the

drive clutch and pull back the

slack. The belt cord line

should be flush with, or

slightly above, the outer cir-

cumference of the driven

clutch sheaves. The belt will

seat itself in the driven clutch

during the break-in period.

Adjust the belt ride-out after

the break-in period by read-

justing belt deflection.

2. To ensure satisfactory belt life, install belts so they operate in the

same direction of rotation by positioning the identification numbers

so that you can read them. If required, separate the sheaves as out-

lined in the belt removal procedures.

3. Turn the driven clutch moveable sheave clockwise while pushing

inward and forcing the belt down between the sheaves.

4. Hold the belt down between the sheaves and roll the bottom portion

over the outer clutch sheave. Work the belt to the outer edge of the

sheave.

5. Rotate the L-wrench to tighten the sheaves. Remove the wrench and

store in the tool kit.

6. Reinstall the side panel.

7. Break in the new belt. See page 69.

104

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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 (X). Bend the track

to check for breakage.

4. Replace the track if any rod

damage is found.

Track Lubrication

The slide rail needs snow for lubrication. Excessive wear indicates

insufficient lubrication. A new rail slide can cause faster heat build-up

in limited lubrication, resulting in excessive wear.

WARNING! Operating with insufficient lubrication between the rail slide and

track guide clips can cause track failure, loss of vehicle control and loss of

braking ability, which can result in serious injury or death. Avoid operating for

extended periods on ice and other surfaces that have little or no snow for

lubrication.

If excessive rail slide wear occurs due to poor snow conditions, addi-

tional wheel kits may be available. See your dealer for more informa-

tion.

Track damage or failure caused by operation on ice or under other poor

lubrication conditions will void the track warranty.

105

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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 cor-

rect tension and alignment.

TRACK TENSION DATA CHART

Measurement

Suspension

Slack Measurement

Weight

Location

RUSH 121

1/4-3/8 inch (6.3-9.6 mm)

10 lbs.

(4.54 kg)

16 inches (40 cm)

ahead of rear

idler shaft

TIP:Tension adjustments should be made only after the track is warmed up and

limber.

1. Turn the engine off.

NOTICE: Do not use the rear bumper to lift the rear of the snowmobile for track

adjustments.

2. Lift the rear of the snowmobile by the chassis (seat support, x-brace

or running boards) until the track is slightly above the ground.

Safely support the rear of the snowmobile in this position.

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.

106

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MAINTENANCE

Track Maintenance

Track Tension

5. Check for specified slack between the wear surface of the track clip

and the plastic slider. Refer to the Track Tension Data Chart on page

106.

If the track needs adjustment:

6. Loosen the rear idler shaft bolt.

7. Loosen the locknuts.

Track Adjusting

Screw

Lock Nut

Slack Measurement

Idler

Shaft

Bolt

Track

16 inches

(40 cm)

10 lbs. (4.54 kg)

8. Tighten or loosen the track adjusting screws to provide equal adjust-

ment on both sides of the track.

9. Repeat the measurement on the other side of the track.

TIP:Check more frequently when the snowmobile is new.

10. Remove the weight. 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 108) and adjust as necessary.

12. Tighten the locknuts.

13. Tighten idler shaft bolts to 35 ft. lbs. (47.5 Nm).

107

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MAINTENANCE

Track Maintenance

Track Alignment

Periodically check that the track is centered and running evenly on the

slide rails. Misalignment will cause excessive wear to the track and slide

rail.

1. Safely support the rear of the snowmobile with the track off the

ground.

2. Start the engine and apply a small amount of throttle until the track

turns slowly at least five complete revolutions. Stop the engine and

let the track come to a stop (do not apply brakes).

3. Inspect track alignment by

looking through the track

window to make sure the

rails 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 lock-

nut and tighten the right

adjusting bolt.

Rails

4. After adjustments are complete, tighten the locknuts and torque

idler shaft bolts to 35 ft. lbs. (47.5 Nm).

5. Repeat steps 2 and 3 to verify proper alignment.

108

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MAINTENANCE

Steering System

Front Suspension Inspection

Each week, or before a long ride, check all steering system fasteners and

tighten if necessary.

109

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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 camber adjustment. See your POLARIS dealer.

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 as camber adjustment may also be affected.

10 in.

(25.4 cm)

10 in.

(25.4 cm)

110

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MAINTENANCE

Steering System

Ski Skags

WARNING! Worn skis and/or skags will adversely affect handling. Loss of

vehicle control may result, causing serious injury or death. See your dealer's

studding chart for recommended skags. If you install longer or more aggressive

carbide skags than the original equipment, it may also be necessary to add track

studs to maintain proper vehicle control while turning on hard-packed snow or

ice.

Check skags before each use of the snowmobile to ensure positive steer-

ing characteristics. Skags must be replaced when worn to half their orig-

inal diameter.

TIP:Carbide skags must be replaced if any abnormal wear or chipping is found.

Skag Replacement

Some models are equipped with single skags. Some models are

equipped with dual skags.

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.

5. Reverse the steps to install a

skag.

Skag

111

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MAINTENANCE

Steering System

Rail Slide Wear

Measure slide thickness at

several points along the rail.

Have your dealer replace the

slide when it's worn down to

the top of the wear limit

7/16 inch

(1.1 cm)

indicator groove. Do not

operate the snowmobile if

slide thickness measures less

than 7/16 inch (1.1 cm).

Rear Suspension

Lubricate the suspension pivot shaft with POLARIS All Season Grease

every 1000 miles (1600 km) and before seasonal storage.

Inspect the rear suspension bushings (X) at the intervals outlined in the

Periodic Maintenance Table beginning on page 81. Inspect more often if

the snowmobile is frequently operated in extreme conditions. Replace

bushings when they show evidence of wear.

Lubricate

112

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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.

Matte Clear Coat Cleaning (if equipped)

Matte finish products are prone to trapping dirt, oils and other contami-

nants. POLARIS Industries recommends cleaning with warm water and

a mild dish detergent. Use a soft sponge to gently rub the surface and

rinse with clean warm water. For stubborn stains such as grease or oil

use a citrus based cleaner (3M Citrus Base Cleaner recommended).

Spray onto the area to be cleaned and rub with a soft sponge. Allow to

sit for a couple of minutes and wash away with clean warm water.

Repeat as necessary to clean the surface.

NOTICE: Never use a polishing/buffing wax or any sponge that has an abrasive

surface. These products will buff the matte surface of the finish result-

ing in a glossy finish. It is not recommended that you clean matte fin-

ishes with a pressure washer as this will further imbed contaminants

into the clear coat and possibly damage the decals.

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 115 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.

113

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MAINTENANCE

Extended Storage

Clutch and Drive System

Remove the drive belt and store in a cool dry location. Do not lubricate

clutch components, except the driven clutch shaft bushing as outlined in

the Master Repair Manual. See your dealer.

Engine Protection

Proper preparation of the engine and fuel system is vital to the preven-

tion of rust and corrosion on precision engine parts during storage.

Whenever the snowmobile is stored for a period of more than 60 days,

the engine must be fogged with fogging oil. Follow the engine fogging

instructions provided on the container.

Always add 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.

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.

114

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricants

Fogging Oil (12 oz. Aerosol)

2870791

2877882

2877953

2877883

2877884

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

2871534

2871323

Polaris Antifreeze 60/40 Premix (qt./.95 l)

Polaris Antifreeze 60/40 Premix (gal./3.8 l)

Additives/Miscellaneous

2871326

2870652

2872189

2872893

2870505

2872889

2872890

Carbon Clean

Fuel Stabilizer

DOT4 Brake Fluid

Engine Degreaser

Isopropyl Fuel De-Icer

Brake and Clutch Cleaner

Carburetor and Throttle Body Cleaner

115

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SPECIFICATIONS

600 RUSH

Capacities and Dimensions

Body Style

Rider Capacity

PRO-RIDE

Coolant Capacity

Chaincase Oil Capacity

Fuel Tank Capacity

5 qts. (4.7 l)

9 oz. (266.2 ml)

11 gal. (41.6 l)

Gearcase Oil Capacity (oz./ml) N/A

Height

46 inches (117 cm)

Length

108 inches (274 cm)

3.8 qts. (3.6 l)

48 inches (122 cm)

Hayes Phantom

11.5 inches (29 cm)

3211122

Oil Capacity (qts./l)

Designed Width (in./cm)

Brake Type

Drive Clutch Center Distance

Drive Belt P/N

Clutch Type

P-85

Reverse Transmission

Electronic Reverse

Engine and Cooling

Engine

S4771-6044-OR6G

Displacement

599 cc

Cylinders

Bore x Stroke (mm)

Alternator Output

Throttle Body

Oil Injection

77.25 x 64

400 watt

Mikuni

VES

Throttle Body Bore Size

Idle RPM

46 mm

1700 +/- 200

Cooling

Liquid

Ignition Type

Digital

Ignition Timing

Spark Plug / Gap

Recommended Fuel Octane

18° @ idle 1700 RPM w/120°F (49°C) water temp

NGK BPR9ES /.027 inches (0.7 mm)

91 recommended (87 minimum)

116

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SPECIFICATIONS

600 RUSH (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.

120/310

(58/42/.45)

P2N

(5137176)

0-600

10-64

130/180 P2 Tab

(7043873)

22:40

72 Pitch

Black

(0-2000)

(1321585)

(7043681)

(58/42/.45)

P2N

(5137176)

600-1200

(2000-4000)

10-62

(1321586)

120/310 Black 130/180 P2 Tab

(7043681) (7043873)

22:40

72 Pitch

(58/42/.45)

P2N

(5137176)

1200-1800

(4000-6000

10-60

(1321587)

120/310 Black 130/180 P2 Tab

(7043681) (7043873)

22:40

72 Pitch

(58/42/.45)

P2N

(5137176)

1800-2400

(6000-8000)

10-58

(1321588)

120/310 Black 130/180 P2 Tab

(7043681) (7043873)

22:40

72 Pitch

(58/42/.45)

P2N

(5137176)

2400-3000

(8000-10000)

10-56

(1321684)

120/310 Black 130/180 P2 Tab

(7043681) (7043873)

20:41

72 Pitch

(58/42/.45)

P2N

(5137176)

3000-3600

(10000-12000)

10 AL

(1321531)

120/310 Black 130/180 P2 Tab

(7043681) (7043873)

20:41

72 Pitch

600 RUSH (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.

(58/42/.45)

P2N

(5137176)

0-600

(0-2000)

10-64

(1321585)

Black/Green

(7042083)

130/180 P2 Tab

(7043873)

22:40

72 Pitch

(58/42/.45)

P2N

(5137176)

600-1200

(2000-4000)

10-62

(1321586)

Black/Green

(7042083)

130/180 P2 Tab

(7043873)

22:40

72 Pitch

(58/42/.45)

P2N

(5137176)

1200-1800

(4000-6000

10-60

(1321587)

Black/Green

(7042083)

130/180 P2 Tab

(7043873)

22:40

72 Pitch

(58/42/.45)

P2N

(5137176)

1800-2400

(6000-8000)

10-58

(1321588)

Black/Green

(7042083)

130/180 P2 Tab

(7043873)

22:40

72 Pitch

(58/42/.45)

P2N

(5137176)

2400-3000

(8000-10000)

10-56

(1321684)

Black/Green

(7042083)

130/180 P2 Tab

(7043873)

20:41

72 Pitch

(58/42/.45)

P2N

(5137176)

3000-3600

(10000-12000)

10 AL

(1321531)

Black/Green

(7042083)

130/180 P2 Tab

(7043873)

20:41

72 Pitch

117

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SPECIFICATIONS

800 RUSH

Capacities and Dimensions

Body Style

Rider Capacity

PRO-RIDE

Coolant Capacity

Chaincase Oil Capacity

Fuel Tank Capacity

5 qts. (4.7 l)

9 oz. (266.2 ml)

11 gal. (41.6 l)

Gearcase Oil Capacity (oz./ml) N/A

Oil Capacity (qts./l)

Height

Length

Designed Width (in./cm)

Brake Type

Drive Clutch Center Distance

Drive Belt P/N

3.8 qts. (3.6 l)

46 inches (117 cm)

108 inches (274 cm)

48 inches (122 cm)

Hayes Phantom

11.5 inches (29 cm)

3211115

Clutch Type

P-85

Reverse Transmission

Electronic Reverse

Engine and Cooling

Engine

S44774-8044-OR8G

Displacement

794 cc

Cylinders

2 Monoblock

Bore x Stroke (mm)

Alternator Output

Throttle Body

Oil Injection

85 x 70

400 watt

Mikuni

VES

Throttle Body Bore Size

Idle RPM

48 mm

1800 +/- 200

Cooling

Liquid

Ignition Type

Digital

Ignition Timing

Spark Plug / Gap

Recommended Fuel Octane

18° @ idle 1700 RPM w/120°F (49°C) water temp

NGK BPR9ES /.027 inches (0.7 mm)

91 recommended (87 minimum)

118

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SPECIFICATIONS

800 RUSH

Clutching Chart

ALTITUDE

Meters

(Feet)

Drive

Clutch

Spring

Chaincase

Gearing/

Pitch

Drive Clutch

Shift Weight

Driven Clutch

Spring

Driven

Helix

N.A.

INTL

*Shaded cells indicate factory settings.

(64/42/.36)

22:36 22:40

0-600

(0-2000)

10-66

(1321584)

120/310 Black LH BLUE/BLACK

(7043681) Team (7043064)

ER (5135401) Pitch

Pitch

(64/42/.36)

22:36 22:40

600-1200

(2000-4000)

10-64

(1321585)

120/310 Black LH BLUE/BLACK

(7043681) Team (7043064)

ER (5135401) Pitch

Pitch

(64/42/.36)

22:36 22:40

1200-1800

(4000-6000

10-62

(1321586)

120/310 Black LH BLUE/BLACK

(7043681)

Team (7043064)

ER (5135401) Pitch

Pitch

LH BLK/PUR

TEAM LW

(7043363)

(64/42/.36)

22:36 22:40

1800-2400

(6000-8000)

10-60

(1321587)

120/310 Black

(7043681)

ER (5135401) Pitch

Pitch

LH BLK/PUR

TEAM LW

(7043363)

(64/42/.36)

20:38 20:41

2400-3000

(8000-10000)

10-60

(1321587)

140/330

(7043342)

ER (5135401) Pitch

Pitch

LH BLK/PUR

TEAM LW

(7043363)

(64/42/.36)

20:38 20:41

3000-3600

(10000-12000)

10-58

(1321588)

140/330

(7043342)

ER (5135401) Pitch

Pitch

119

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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 mal-

function

• SEE YOUR DEALER.

• Replace the drive belt.

• SEE YOUR DEALER.

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 appli- • Replace the drive belt.

cation

Clutch alignment out • SEE YOUR DEALER.

of spec

Engine mount bro-

ken 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.

120

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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 drive shaft

• 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 bro-

ken

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, inade-

quate fuel supply, broken parts or

improper cooling.

Hydrostatic lock

• Fuel may have entered the crankcase

while the vehicle was standing or

being transported. SEE YOUR

DEALER to correct the cause. Drain

plug(s) are located on the lower

crankcase for emergency draining.

121

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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 the fuel tank contains

fuel.

• Ice may be in the fuel line, filter or

pump. Add isopropyl alcohol to the

fuel system.

Poor engine com-

pression

• This indicates a major engine prob-

lem 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)

• SEE YOUR DEALER.

Engine continually

backfires

• Change plug(s), ensure caps are

seated.

Fuel System

• Dirt or ice may be in the fuel system

(deicer should be added to non-etha-

nol fuel at all times for assurance

against fuel line icing).

Incorrect throttle

freeplay or faulty

switch

• SEE YOUR DEALER.

Engine requires

more than normal

pulls to start

Poor fuel

• Replace with fresh winter fuel.

Not enough fuel get- • SEE YOUR DEALER.

ting to engine

Plugged fuel filter or • SEE YOUR DEALER.

tank pick-up sock

122

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TROUBLESHOOTING

Suspension Troubleshooting

Problem

Solution

Rear suspension

bottoms too easily

• Adjust rear shock spring (see pages 47 and 55).

• Change rear shock spring (see your dealer).

• Revalve rear track shock (see your dealer).

Rides too stiff in rear • Check for binding suspension shafts and grease all pivot

points.

• Adjust rear shock spring (see pages 47 and 55).

• Change rear shock spring (see your dealer).

• Check track tension (see page 106).

Too much weight

transfer when

climbing

• Adjust rear shock spring (see pages 47 and 55).

Too little weight

transfer when

climbing

• Adjust rear shock spring (see pages 47 and 55).

Machine darts from

side to side

• Check ski alignment (see page 110).

• 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.

• Adjust rear shock spring (see pages 47 and 55).

• Check rail slide/replace if worn (see page 112).

• Install Accu-Trak dual skags (see your dealer).

Front end pushes

Steering is heavy

• Check for worn skags.

• Adjust rear shock spring (see pages 47 and 55).

• Check for binding front suspension shafts and steering

components, grease all pivot points (elevate front of snow-

mobile).

• Increase IFS preload (if equipped) (see page 51).

• Install single skag (see your dealer).

• Make sure spindles and all steering components turn freely.

• Check ski alignment (see page 110).

• Check skags and skis for damage.

• Adjust rear shock spring (see pages 47 and 55).

123

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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

124

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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 war-

ranty. 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: 1-888-704-5290

Canada: 1-204-925-7100

POLARIS Anti-Theft System

The POLARIS anti-theft system (PATS) monitoring program is designed to aid owners

of registered snowmobiles in recovery of stolen machines.

Administration

1. POLARIS snowmobile owner reports theft.

A. In addition to notifying the proper law enforcement officials, the owner must call

POLARIS Customer Service.

B. Owners must provide their name, address, telephone number and the model and

serial number of stolen machines.

2. POLARIS warranty will provide all dealerships with a monthly updated list of all

stolen units to further monitor thefts.

3. POLARIS warranty will aid in notifying the proper owner when a unit is recovered.

125

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WARRANTY

Limited Warranty

POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR

LIMITED WARRANTY on all components of the POLARIS snowmobile against

defects in material or workmanship. Warranty period will vary regionally. This warranty

covers the parts and labor charges for repair or replacement of defective parts that are

covered by this warranty. The warranty begins on the date of purchase. This warranty is

transferable to another consumer, during the warranty period, through a POLARIS

dealer.

Registration

At the time of sale, the Warranty Registration Form must be completed by your dealer

and submitted to POLARIS within ten days. Upon receipt of this registration, POLARIS

will record the registration for warranty. No verification of registration will be sent to

the purchaser as the copy of the Warranty Registration Form will be the warranty entitle-

ment. If you have not signed the original registration and received the customer copy,

please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.

Initial dealer preparation and setup of your snowmobile is very important in ensuring

trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer

setup will void your warranty coverage.

Warranty Coverage and Exclusions

Limitations of warranties and remedies

This warranty excludes any failures not caused by a defect in material or workmanship.

The warranty does not cover accidental damage, normal wear and tear, abuse or

improper handling. The warranty also does not cover any snowmobile that has been

structurally altered, neglected, improperly maintained, used for racing or used for pur-

poses other than for which it was manufactured. The warranty does not cover any dam-

ages that occur during trailer transit or as a result of unauthorized service or parts. In

addition, this warranty does not cover physical damage to paint or finish, stress cracks,

tearing or puncturing of upholstery material, corrosion or defects in parts, components

or the snowmobile due to fire, explosions or any other cause beyond POLARIS' control.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that

are not compatible with the snowmobile.

The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive

option, repair or replacement of any defective materials, or components or products.

THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES

AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS

SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-

QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARIS-

ING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT,

NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CON-

SEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT

FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY

FAILED OF ITS ESSENTIAL PURPOSE. Some states do not permit the exclusion or

limitation of incidental or consequential damages or implied warranties, so the above

limitations or exclusions may not apply to you if inconsistent with controlling state law.

126

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WARRANTY

Limitations of warranties and remedies

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR

WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-

RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations

on how long an implied warranty lasts, so the above limitation may not apply to you if

inconsistent with controlling state law.

Promotional Warranties

Promotional warranties are sometimes offered by POLARIS. These warranties can be,

but are not limited to:

•

Two-year extended engine coverage

Two-year powertrain coverage

Extended service contract

If you selected any type of extended warranty coverage as part of a POLARIS retail pro-

gram, please contact any authorized POLARIS dealer for additional information.

How to Obtain Warranty Service

If your snowmobile requires warranty service, you must take it to a POLARIS dealer

authorized to repair POLARIS snowmobiles. When requesting warranty service you

must present your copy of the Warranty Registration form to the dealer. (The cost of

transportation to and from the dealer is YOUR responsibility). POLARIS recommends

that you use your original selling dealer; however, you may use any POLARIS Servicing

Dealer to perform warranty service.

Please work with your dealer to resolve any warranty issues. Your dealer will contact the

appropriate personnel at POLARIS if additional assistance is needed.

This warranty gives you specific legal rights, and you may also have other rights which

vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty

terms will remain in effect.

Engine Oil

1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-

ommend the use of POLARIS engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered

by warranty.

127

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WARRANTY

Conditions and Exclusions

In order to qualify for warranty, the product must have been properly set up and tested

by a POLARIS Dealer (if applicable). Failure of any dealer to perform the required vehi-

cle Pre-Delivery Inspection, perform all applicable service bulletins and have the con-

sumer sign the PDI form prior to delivery may void the warranty. Failure to provide

proof of required periodic maintenance upon request may result in denial of warranty

coverage. Use of the recommended POLARIS products for lubrication and maintenance

as directed by the Owner's manual is highly recommended. Should a failure occur dur-

ing the warranty period resulting from the use of non-recommended products, warranty

coverage may be denied.

Warranty does not apply to parts exposed to friction surfaces, stresses, environmental

conditions and/or contamination. The following items are excluded from warranty con-

sideration if the failure was due to wear or not the direct result of a defect:

Skis

Ski wear rods

Tracks

Slide rails

Suspension components

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

Light bulbs/Sealed beam lamps

Idler wheels

Warranty applies to the product only and does not allow for coverage of personal loss.

Some items are considered "consumable," meaning they are considered part of normal

maintenance or part of completing an effective repair. The following items are excluded

from warranty coverage in the event of a warranty claim:

Spark Plugs

Filters

Fuel

Lubricants such as oil, grease, etc.

Batteries (unless defective)

Cosmetic damage/repair

Coolants

Sealants

Hotel fees

Meals

Towing charges

Mileage

Rentals/Loss of product use

Shipping/ handling fees

Product pick-up/delivery

Loss of vacation/personal time

This warranty also excludes failures resulting from improper lubrication; improper

engine timing; improper fuel; surface imperfections caused by external stress, heat, cold

or contamination; operator error or abuse; improper component alignment, tension,

adjustment or altitude compensation; failure due to snow, water, dirt or other foreign

substance ingestion/contamination; improper maintenance; modified components; use

of aftermarket components resulting in failure; unauthorized repairs; repairs made after

the warranty period expires or by an unauthorized repair center; use of the product in

competition or for commercial purposes. Warranty will not apply to any product which

has been damaged by abuse, accident, fire or any other casualty not determined a defect

of materials or workmanship.

128

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WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-

RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD

OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-

TION.

This policy does not apply to vehicles that have received authorization for export from

POLARIS Industries. Dealers may not give authorization for export. You should consult

an authorized dealer to determine this vehicle's warranty or service bulletin coverage if

you have any questions.

This policy does not apply to vehicles registered to government officials or military per-

sonnel on assignment outside the country of the selling dealer's authorized location.

This policy does not apply to Safety Bulletins.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If

you move or are traveling within the country where your vehicle was purchased, War-

ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer

who sells the same line as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased,

you should take your vehicle to an authorized POLARIS dealer. You must show the

dealer photo identification from the country of the selling dealer's authorized location as

proof of residence. Upon residence verification, the servicing dealer will be authorized

to perform the warranty repair.

129

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WARRANTY

Exported Vehicles

How to Get Service

If You Move:

If you move to another country, be sure to contact POLARIS Customer Assistance and

the customs department of the destination country before you move. Vehicles importa-

tion rules vary considerably from country to country. You may be required to present

documentation of your move to POLARIS Industries in order to continue your warranty

coverage. You may also be required to obtain documentation from POLARIS Industries

in order to register your vehicle in your new country. You should warranty register your

vehicle at a local POLARIS dealer in your new country immediately after you move to

continue your warranty coverage and to ensure that you receive safety information and

notices regarding your vehicle.

If Purchased From A Private Party:

If you purchase a POLARIS product from a private citizen outside of the country in

which the vehicle was originally purchased, all warranty coverage will be denied. You

must nonetheless warranty register your vehicle under your name and address with a

local POLARIS dealer in your country to ensure that you receive safety information and

notices regarding your vehicle.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have

not followed the procedure set out above, your vehicle will no longer be eligible for war-

ranty or service bulletin coverage of any kind, other than safety bulletins. (Vehicles reg-

istered to Government officials or military personnel on assignment outside of the

country where the vehicle was purchased will continue to be covered by the basic war-

ranty.)

For questions call POLARIS Customer Assistance (see page 125).

130

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the POLARIS standard limited war-

ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur-

chased, this emissions-certified vehicle is designed, built and equipped so it conforms

with applicable U.S. Environmental Protection Agency emission regulations. POLARIS

warrants that the vehicle is free from defects in materials and workmanship that would

cause it to fail to meet these regulations.

The warranty period for this emissions-certified vehicle starts on the date the vehicle is

first purchased and continues for a period of 200 hours of engine operation, 4000 kilo-

meters (2485 miles) of vehicle travel, or 30 calendar months from the date of purchase,

whichever comes first.

This emissions limited warranty covers components whose failure increases the vehi-

cle’s regulated emissions, and it covers components of systems whose only purpose is to

control emissions. Repairing or replacing other components not covered by this war-

ranty is the responsibility of the vehicle owner. This emissions limited warranty does not

cover components whose failure does not increase the vehicle’s regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to

the following systems:

•

Air-induction system

Fuel system

•

Ignition system

Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust emis-

sions:

•

Aftertreatment devices

Crankcase ventilation valves

•

Sensors

Electronic control units

The following parts are considered emission-related components for evaporative emis-

sions:

•

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.

131

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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 WAR-

RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-

DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-

RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR

OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND

SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY

FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR-

POSE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-

TIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on

how long an implied warranty lasts, so the above limitation may not apply if it is incon-

sistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workman-

ship.This limited warranty does not cover damage due to accidents, abuse or improper

handling, maintenance or use. This limited warranty also does not cover any engine that

has been structurally altered, or when the vehicle has been used in racing competition.

This limited warranty also does not cover physical damage, corrosion or defects caused

by fire, explosions or other similar causes beyond the control of POLARIS.

Owners are responsible for performing the scheduled maintenance identified in the

owner's manual. POLARIS may deny warranty claims for failures that have been caused

by the owner’s or operator’s improper maintenance or use, by accidents for which

POLARIS has no responsibility, or by acts of God.

Any qualified repair shop or person may maintain, replace, or repair the emission con-

trol devices or systems on your vehicle. POLARIS recommends that you contact an

authorized POLARIS dealer to perform any service that may be necessary for your vehi-

cle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential

violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer

reduces the effectiveness of the vehicle's emission controls. Tampering with emission

controls is prohibited by federal law.

If you have any questions regarding your warranty rights and responsibilities, please

contact the POLARIS Warranty Department at 1-888-704-5290.

132

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MAINTENANCE LOG

Present this section of your manual to your dealer each time your snow-

mobile is serviced. This will provide you and future owners with an

accurate log of maintenance and services performed on the snowmobile.

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

133

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

134

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MAINTENANCE LOG

DATE

MILES

(KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

135

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . . 57

Air Pollution . . . . . . . . . . . . . . . . . . . . 6

Avalanches. . . . . . . . . . . . . . . . . . . . . 15

DET. . . . . . . . . . . . . . . . . . . . . . . . 28-29

Diagnostic Display Codes. . . . . . . 44-45

Diagnostic Display Mode . . . . . . . . . . 43

Disabled Operators . . . . . . . . . . . . . . . 12

Display, Standard/Metric . . . . . . . . . . 36

Drive Belt

Adjustment . . . . . . . . . . . . . . . . 102

Break-In. . . . . . . . . . . . . . . . . . . . 69

Condition. . . . . . . . . . . . . . . . . . 101

Deflection . . . . . . . . . . . . . . . . . 102

Installation. . . . . . . . . . . . . . . . . 104

Removal . . . . . . . . . . . . . . . . . . 103

Safety. . . . . . . . . . . . . . . . . . . . . . 18

Drive Chain Tension . . . . . . . . . . . . . . 95

Driver Awareness . . . . . . . . . . . . . . . . 14

Driveshaft Bearing Lubrication. . . . . . 85

Driving Downhill . . . . . . . . . . . . . . . . 17

Driving in Hilly Terrain . . . . . . . . . . . 17

Driving on Slippery Surfaces . . . . . . . 16

Driving Responsibly . . . . . . . . . . . . . . 19

Belt Break-In . . . . . . . . . . . . . . . . . . . 69

Brake Lever Travel Inspection . . . . . 63

Brakelight Replacement. . . . . . . . . . . 99

Brakes . . . . . . . . . . . . . . . . . . . 63, 96-98

Brake Fluid . . . . . . . . . . . . . . . . 97

Components. . . . . . . . . . . . . . . . 96

Inspection. . . . . . . . . . . . . . . . . . 96

Lever Travel. . . . . . . . . . . . . . . . 96

System Bleeding . . . . . . . . . . . . 98

Break-In Period . . . . . . . . . . . . . . . 68-69

Carbide Skags . . . . . . . . . . . . . . . . . . 59

Chaincase Oil. . . . . . . . . . . . . . . . . . . 86

Cleaning for Matte Finishes. . . . . . . 113

Cleaning/Preservation for Storage. . 113

Clicker, Front Track Shock . . . . . . . . 54

Clicker, IFS Shock. . . . . . . . . . . . . . . 52

Clicker, Rear Shock. . . . . . . . . . . . . . 55

Clicker, Rebound (800 LE) . . . . . . . . 52

Clutch Alignment Offset . . . . . . . . . 100

Clutch Safety . . . . . . . . . . . . . . . . . . . 18

Clutch System . . . . . . . . . . . . . . 100-104

Clutch Warning . . . . . . . . . . . . . . . . . 21

Clutch/Drive System, Storage . . . . . 114

Clutching Charts

600 RUSH . . . . . . . . . . . . . . . . 117

800 RUSH . . . . . . . . . . . . . . . . 119

Cold Weather Drive-Away . . . . . . . . 18

Compression Damping

Front Track Shock . . . . . . . . . . . 54

IFS Shock . . . . . . . . . . . . . . . . . 52

Coolant. . . . . . . . . . . . . . . . . . . . . . . . 91

Coolant Level. . . . . . . . . . . . . . . . . . . 91

Cooling System . . . . . . . . . . . . . . . 91-93

Cooling System, Bleeding . . . . . . . . . 93

Cooling System, Flushing . . . . . . . . . 92

Customer Service. . . . . . . . . . . . . . . 125

Electrical Connections, Storage . . . . 114

Emission Control Information. . . . . . . 80

Emissions Limited Warranty. . . 131-132

Engine Break-In . . . . . . . . . . . . . . 68-69

Engine Overheating. . . . . . . . . . . . . . . 92

Engine Protection for Storage . . . . . . 114

Engine Restarting . . . . . . . . . . . . . . . . 67

Engine Safety . . . . . . . . . . . . . . . . . . . 10

Engine Starting . . . . . . . . . . . . . . . . . . 67

Engine Stop Switch. . . . . . . . . . . . . . . 74

Environment Preservation. . . . . . . . . . . 6

Exhaust System . . . . . . . . . . . . . . . . . . 94

Fasteners, Hood and Side Panel . . . . . 65

Fluid Change

Chaincase . . . . . . . . . . . . . . . . . . 86

Coolant . . . . . . . . . . . . . . . . . . . . 92

Fluid Level

Brake Fluid . . . . . . . . . . . . . . . . . 97

Chaincase . . . . . . . . . . . . . . . . . . 86

Coolant . . . . . . . . . . . . . . . . . . . . 91

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INDEX

Front Suspension Inspection. . . . . . . 109

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . 87

Fuel Lines . . . . . . . . . . . . . . . . . . . . . . 87

Fuel Premix (Initial Fill). . . . . . . . . . . 68

Fuel Pump. . . . . . . . . . . . . . . . . . . . . . 87

Fuel Recommendation . . . . . . . . . . . . 72

Fuel System Deicers . . . . . . . . . . . . . . 72

Fuel Type Selection . . . . . . . . . . . . . . 27

Fuel Warnings. . . . . . . . . . . . . . . . . . . 71

Maintenance Interval Table . . . . . 82-84

Maintenance Program. . . . . . . . . . . . . 81

Maintenance Recommendations. . . . . . 9

Maneuverability . . . . . . . . . . . . . . . . . 18

Matte Finish Cleaning . . . . . . . . . . . 113

Metric/Standard Display. . . . . . . . . . . 36

Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Odometer/Engine Hour Display. . . . . 35

Oil Change, Chaincase . . . . . . . . . . . . 86

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . 90

Oil Injection System. . . . . . . . . . . . . . 69

Oil Level, Chaincase . . . . . . . . . . . . . 86

Oil Level, Injection. . . . . . . . . . . . . . . 73

Oil Lines. . . . . . . . . . . . . . . . . . . . . . . 90

Oil Recommendations . . . . . . . . . . . . 68

Operating in Deep Snow . . . . . . . . . . 16

Operation Warning. . . . . . . . . . . . . . . 23

Operator Safety. . . . . . . . . . . . . . . . 8-20

Overheating, Engine. . . . . . . . . . . . . . 92

Guide, Suspension Set-Up . . . . . . 46-49

Handlebar Adjustments. . . . . . . . . . . . 56

Handlebar Angle. . . . . . . . . . . . . . . . . 56

Handlebar Position . . . . . . . . . . . . . . . 56

Headlight Adjustment. . . . . . . . . . . . . 26

Headlight Lamp Replacement . . . . . . 99

Hood Fasteners . . . . . . . . . . . . . . . . . . 65

Hood/Side Panel Access . . . . . . . . . . . 85

Ice and Snow Build-up . . . . . . . . . . . . 16

IFS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

IFS Adjustment Options . . . . . . . . . . . 50

IFS Components . . . . . . . . . . . . . . . . . 50

Ignition Lock System . . . . . . . 29, 37-42

Inadequate Snow Conditions . . . . . . . 16

Independent Front Suspension . . . . . . 50

Indicator Lights. . . . . . . . . . . . . . . . . . 31

Information Display Area . . . . . . . . . . 34

Inspection, Pre-Ride . . . . . . . . . . . . . . 60

Instrument Cluster. . . . . . . . . . . . . 30-45

Intake Filters . . . . . . . . . . . . . . . . . . . . 87

Intake Silencer . . . . . . . . . . . . . . . . . . 18

Parking Brake Lever Lock . . . . . . . . . 64

Passenger Warning. . . . . . . . . . . . . . . 22

Playback Function . . . . . . . . . . . . . . . 35

Polaris Products and Part Numbers . 115

Preload, Front Track Shock Spring . . 54

Preload, IFS Shock Spring . . . . . . . . . 51

Preload, Rear Shock Spring . . . . . . . . 55

Pre-Ride Checklist . . . . . . . . . . . . . . . 60

Pre-Ride Suspension Inspection. . . . . 61

Pressure Cap Warning . . . . . . . . . . . . 21

Rail Slide Wear . . . . . . . . . . . . . . . . 112

Rebound Clicker (800 LE) . . . . . . . . . 52

Recoil Rope Inspection . . . . . . . . . . . 65

Registration, Warranty . . . . . . . . . . . 126

Reverse Operation . . . . . . . . . . . . 77-78

Reverse Warning . . . . . . . . . . . . . . . . 22

Lights

Headlight Replacement. . . . . . . . 99

Taillight/Brake Light . . . . . . . . . 99

Lubrication . . . . . . . . . . . . . . . . . . 85-86

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INDEX

Rider Capacity . . . . . . . . . . . . . . . . . . 13

Rider Information Center. . . . . . . . 32-45

Riding Apparel. . . . . . . . . . . . . . . . . . 11

Riding Position . . . . . . . . . . . . . . . . . 10

Suspension Adjustments, Front. . . 50-52

Suspension Adjustments, Rear . . . 53-55

Suspension Inspection, Pre-Ride. . . . . 61

Suspension Inspection, Rear . . . . . . . 112

Suspension Performance Tips. . . . . . . 53

Suspension Quick Set-Up Guide. . 46-49

Switches

Safety Labels . . . . . . . . . . . . . . . . . 21-23

Safety Symbols . . . . . . . . . . . . . . . . . . 8

Security System . . . . . . . . . . . . 29, 37-42

Set-Up Guide, Suspension. . . . . . . 46-49

Shock Clicker, Rear Shock . . . . . . . . 55

Shock Clicker, Rebound (800 LE). . . 52

Shock Lubrication, Rear Shock. . . . . 85

Shock Springs, Rear. . . . . . . . . . . . . . 48

Shock Valving, IFS . . . . . . . . . . . . . . 52

Side Panel Access . . . . . . . . . . . . . . . 85

Side Panel Fasteners . . . . . . . . . . . . . 65

Signal Words . . . . . . . . . . . . . . . . . . . . 8

Skags, Carbide. . . . . . . . . . . . . . . . . . 59

Ski Alignment . . . . . . . . . . . . . . . . . 110

Ski Skags . . . . . . . . . . . . . . . . . . . . . 111

Slide Rail and Track Cooling . . . . . . 70

Snow Conditions . . . . . . . . . . . . . . . . 16

Spark Plug Condition. . . . . . . . . . . . . 89

Spark Plug Inspection . . . . . . . . . . . . 89

Spark Plug Recommendations. . . . . . 88

Spark Plugs . . . . . . . . . . . . . . . . . . 88-89

Speed . . . . . . . . . . . . . . . . . . . . . . . . . 13

Speed Display . . . . . . . . . . . . . . . . . . 34

Spring Guide, Rear Shock . . . . . . . . . 48

Spring Preload, Front Track Shock . . 54

Spring Preload, IFS Shock. . . . . . . . . 51

Spring Preload, Rear Shock. . . . . . . . 55

Standard/Metric Display . . . . . . . . . . 36

Starting the Engine . . . . . . . . . . . . . . 67

Starting the Engine, Restarting . . . . . 67

Steering System . . . . . . . . . . . . . 109-112

Steering System Inspection . . . . . . . . 65

Stopping, Emergency. . . . . . . . . . . . . 76

Storage Procedures . . . . . . . . . . 113-114

Storage, Daily . . . . . . . . . . . . . . . . . . 79

Studs . . . . . . . . . . . . . . . . . . . . . . . . . 58

Survival Preparation . . . . . . . . . . . . . 12

Engine Stop Switch. . . . . . . . . . . 74

Mode/Select Buttons . . . . . . . . . . 30

Mode/Set Switch . . . . . . . . . . . . . 30

Throttle Safety Switch. . . . . . . . . 74

Taillight/Brakelight Replacement . . . . 99

Throttle Lever . . . . . . . . . . . . . . . . . . . 75

Throttle Lever Inspection . . . . . . . . . . 62

Throttle Safety Switch. . . . . . . . . . . . . 74

Throttle Safety Switch Inspection. . . . 62

Towing . . . . . . . . . . . . . . . . . . . . . . . . 79

Track

Alignment . . . . . . . . . . . . . . . . . 108

Inspection . . . . . . . . . . . . . . . . . 105

Lubrication . . . . . . . . . . . . . . . . 105

Tension . . . . . . . . . . . . . . . 106-107

Track Care for Storage . . . . . . . . . . . 114

Track Inspection . . . . . . . . . . . . . . . . . 65

Track Maintenance . . . . . . . . . . 105-108

Track Safety . . . . . . . . . . . . . . . . . . . . 10

Track Tension . . . . . . . . . . . . . . . . . . . 53

Track Warm-Up . . . . . . . . . . . . . . . . . 70

Track Warning . . . . . . . . . . . . . . . . . . 22

Traction Products . . . . . . . . . . . . . 58-59

Transporting the Snowmobile. . . . . . 114

Troubleshooting, Drive Belt . . . . . . . 124

Troubleshooting, Engine. . . . . . 120-122

Troubleshooting, Suspension . . . . . . 123

Tune-Up . . . . . . . . . . . . . . . . . . . . . . 113

Vehicle Identification Numbers . . . . . . 7

Wear Strips . . . . . . . . . . . . . . . . . . . . . 59

Windchill. . . . . . . . . . . . . . . . . . . . . . . 20

138

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