Polaris 2014 550 INDY 144, Owner'S Manual

Page 1: ...PMS 419 Snowmobile Owner s Manual for Maintenance and Safety 550 INDY 144 550 INDY LXT 550 INDY Adventure 550 INDY Voyager ...

Page 2: ...ons 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 ...

Page 3: ...d recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but infor...

Page 4: ... information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided ...

Page 5: ... and features The Perfect Fit 34 This section includes suspension set up information and explains how to make additional suspension adjustments for the perfect riding experience Pre Ride Inspections 42 This section explains procedures that must be performed before riding Operation 49 This section explains proper engine break in operation of features and general operating procedures Maintenance 63 ...

Page 6: ...obile 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 practi...

Page 7: ...hat snowmobiles conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter m...

Page 8: ...ng a POLARIS key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number ___________________________________________________ Tunnel VIN right side of tunnel ____________________________________________ Engine Serial Number on recoil housing ____________________________________ Key Number _______________________________________________...

Page 9: ...ous 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 ind...

Page 10: ...s 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 aero...

Page 11: ...Turn off the ignition open the side panels or hood make the adjustment secure shields and guards secure the side panels and hood and then restart the engine to check its operation WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments Riding Position Operating a snowmobile requires skill and balance for pro...

Page 12: ...er will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be pre...

Page 13: ...in a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the conditions you may encounter Such equipment may include but is not limited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a...

Page 14: ...andles and running boards footrests 5 Make sure both driver and passenger are wearing appropriate riding gear including an approved helmet 6 Perform the recommended pre ride inspections See page 42 7 Lock the parking brake when loading a passenger Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger mounts or dismounts Unlock the parking brake before ...

Page 15: ...he driver 14 Make sure your passenger has read and understands the instructions and warnings in this manual 15 Never remove your hands from the handlebars while operating and always keep both feet on the running boards footrests Passenger s Responsibilities 1 Read and understand this owner s manual Review all warnings and labels 2 Always remain seated in the passenger seat and facing forward with ...

Page 16: ...elf a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Never travel on frozen bodies of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the snowmobile you and your cargo together with any other vehicles in your party Always check with local authoritie...

Page 17: ...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 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 red...

Page 18: ... snow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in mountainous terrain Before riding in mountainous terrain call or log on to your local avalanche advisory to get current weather and snow stability information Fo...

Page 19: ...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 fres...

Page 20: ... 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 hi...

Page 21: ... not attempt to service the clutches All clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynamically balanced before installation Any tampering may disrupt this precision balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time especially overnight al...

Page 22: ...ell as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions Your snow...

Page 23: ...3 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min 5 min Wind Speed in Km h Actual Thermometer Reading C 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 Equivalent Temperature C Calm 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 3 0 4 7 11 14 18 22 25...

Page 24: ...t number is printed on the label Clutch Warning Belt Removal This warning label is found on the clutch cover 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 BELT REMOVAL ALL UNITS 1 For electric revers...

Page 25: ... 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 Machine stopped and engine at idle push yellow button on LH control to reverse Flashing light on dash indicates reverse ...

Page 26: ...peed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes to avoid unexpected obstacles or to stop safely Never consume alcohol or drugs before or while operating this vehicle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop A...

Page 27: ...f ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for long periods Do not leave brake engaged for more than five minutes Before starting engine check throttle brake and steering for proper opera tion Make sure hood and side panels are latched Be sea...

Page 28: ...dlight 9 Windshield if equipped 10 Handlebar 11 Fuel Filler Cap 12 Operator Seat 13 Passenger Seat if equipped 14 Passenger Backrest if equipped 15 Cargo Rack if equipped 16 Taillight 17 Rear Bumper 18 Snow Flap 19 Suspension 20 Track 21 Side Panel 22 Side Panel Fasteners 22 21 11 13 14 15 ...

Page 29: ...n Switch 3 Engine Stop Switch 4 Recoil Starter Handle 5 Brake Lever 6 Parking Brake Lock 7 Handlebar Grip Warmer Switch 8 Thumbwarmer Switch 9 Electronic Reverse Button 10 Headlight Dimmer Switch 11 Tool Kit Storage Bag 2 3 4 1 9 10 6 7 8 5 11 ...

Page 30: ...er grab handles can be adjusted for rider preference 1 Remove the hardware securing the grab handles to the grab handle tube 2 Reposition the grab handles to one of the three available positions and reinstall the hardware securely Cargo Storage The maximum weight capacity for the cargo area is 30 lbs 14 kg Always secure cargo before operating Do not exceed the weight limit Up Down Adjustment Posit...

Page 31: ...wmobile Use of unapproved parts and accessories may result in Non compliance with government industry requirements Voiding of warranty Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems Exhaust systems are critical safety areas that must use approved POLARIS parts Please see your POLARIS dealer for service ...

Page 32: ...roducts will damage the lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Immediately clean off any gasoline that splashes on the instrument cluster Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h Rider Information Center MODE Button Speedometer Indicator Lamps ...

Page 33: ...sion is in reverse See page 60 High Beam The high beam indicator illuminates when the lights are set to high beam Parking Brake This indicator illuminates when the parking brake is engaged It will also illuminate when the service brake is in use See page 46 Low Oil The low oil indicator light may flicker at times due to oil movement in the bottle but when the light comes on and remains on while at...

Page 34: ...th the vehicle powered by an external DC power supply connector The information center is set to display standard units of measurement at the factory To change to metric see page 33 Information Display Area This area displays either engine speed engine temperature or maximum vehicle speed Odometer Engine Hour Display This area displays the odometer trip meters and engine hours MODE Button Trip 12 ...

Page 35: ...ce traveled by the vehicle if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displ...

Page 36: ...er to rider depending on rider weight vehicle speed riding style and trail conditions We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The snowmobile should be methodically tested one change at a time under the same conditions trail and snow conditions vehicle speed riding position etc after each adjustment until the best ride i...

Page 37: ...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 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...

Page 38: ...ents involve a compromise or trade off For example a suspension set up for snowcross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bottom out harshly on a snowcross course Refer to the suspension setup label on your snowmobile or see your POLARIS dealer for initial suspension setup information Additional adjustments can be made after initial setup M...

Page 39: ...rmance over worn rail slide It can also improve top speed When riding on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are available from your dealer POLARIS offers track kits for improved flotation in deep snow See your dealer for assistance Tip Keep the suspension pivot points lubricated This will reduce moisture and rust ...

Page 40: ...e snowmobile to remove the weight from the suspension 2 Use a tape measure to measure the spring installed length between the two spring retainers 3 Refer to the chart on page 39 to determine the correct spring length for rider weight If adjustment is needed clear away any snow or ice trapped within the spring or threads 4 Using a spanner wrench rotate the spring to adjust length NOTICE Never adju...

Page 41: ...uspension off the ground Shaded cells indicate factory settings Lbs kg Inches cm 160 73 550 INDY Adventure Voyager LXT 11 1 8 28 2 550 INDY 144 160 220 73 100 550 INDY Adventure Voyager LXT 10 3 4 27 3 550 INDY 144 10 1 2 26 7 220 280 100 127 550 INDY Adventure Voyager LXT 10 1 2 26 7 550 INDY 144 10 1 8 25 7 280 340 127 154 550 INDY Adventure Voyager LXT 10 1 8 25 7 550 INDY 144 9 3 4 Maximum Adj...

Page 42: ... Inspect skags frequently Worn skags may reduce steering and braking control on hard packed snow and ice Replace worn skags to maintain proper balance and vehicle control WARNING Loss of control can result in serious personal injury or death Proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard packed snow or ice See your dealer for a...

Page 43: ...y 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 35 in lbs 4 Nm...

Page 44: ...7 Chaincase Oil Level 70 Injection Oil Level 56 Parking Brake Lock Brake Lever Brake System 45 46 78 Auxiliary Shut Off Switch Engine Stop Switch 48 Ignition Switch 48 Headlight Taillight Brakelight 48 Suspension Mounting Bolts 43 Skags Wear Bars 91 Ski Saddle and Spindle Bolts 43 Hood and Side Panel Fasteners 68 Throttle Lever Safety Switch 58 44 Rear Wheel Idler Bolts 87 Tether Switch Strap if e...

Page 45: ...wing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 87 Rear idler adjusting bolt locknuts Tightness Torque arm bolts Tightness Carrier and bogie wheel bolts Tightness Front torque arm limiter strap Condition Rail slide Condition 91 Track Tension 86 All rear suspension components Lubrication 69 Ski runner skag Con...

Page 46: ...al 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 posi...

Page 47: ...ates low brake fluid level or air in the hydraulic system Refer to the brake bleeding information on page 80 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 79 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always h...

Page 48: ...place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever ti...

Page 49: ...NG Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions Hood and Side Panel Fa...

Page 50: ... 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 operat...

Page 51: ...NOTICE 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 equipped with electric start turn the key to START to crank the engine Release the key to the ON position when the engine starts 6 If not equipped with electric start grasp the starter handle and pull slowly until the recoil engages then pull abruptly to crank t...

Page 52: ...he engine stop switch and throttle safety switch SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Choke Floods engine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Throttle Safety Switch Interrupts ignition circuit All Tether Switch accessory Interrupts ignition circuit All ...

Page 53: ...ns 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 Oil Recommendat...

Page 54: ...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 56 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 Dri...

Page 55: ...e stand to securely support the rear of the snowmobile at the rear bumper The track should be about 4 inches 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions TIP It will take longer to warm up the track sufficiently during colder outdoor temperatures 4 Release the throttle apply th...

Page 56: ...s or death in a short time Turn the fuel valve off whenever the snowmobile is stored parked or transported The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Fuel Recommendation Your POLARIS engine is designed to run on 87 octane non oxygenated or 89 octane oxygenated ...

Page 57: ...h up to 10 ethanol sometimes labeled oxygenated do not add deicers or additives that contain any form of alcohol Fuel Valve The fuel valve is located near the lower rear area of the oil bottle Turn the fuel valve off whenever the snowmobile is stored parked or transported Turn the fuel valve clockwise to OFF to shut off the fuel supply Turn the valve counter clockwise to ON to turn the fuel supply...

Page 58: ...nded replacement parts Carburetion NOTICE Making non recommended adjustments could result in vehicle or engine damage as well as denial of warranty claims We recommend that all carburetor adjustments be performed by your POLARIS dealer Proper carburetor adjustment is critical A lean mixture too much air too little fuel may result in piston burning bearing failure or complete engine failure A rich ...

Page 59: ...nstalled in produc tion is not correct for all altitudes and or temperatures See page 75 for more information NOTICE A main jet that s too small will cause a lean operating condition and may cause serious engine damage Jet the carburetors carefully for elevation and temperature according to the jetting charts See the specifications section beginning on page 98 TIP It s the owner s responsibility t...

Page 60: ...y 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...

Page 61: ...f 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...

Page 62: ...ng the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your vehicle is clear 3 Push the yellow reverse button on the left hand control for one second then release The engine will automatically reduce R...

Page 63: ... instrument panel will shut off 3 Apply the throttle slowly to make sure the transmission is in forward High Altitude Setting At altitudes above 6000 feet 1800 m the engine will require a different ignition setting to improve the success of the reverse system To set for a higher altitude start the engine and hold the reverse button down until the light on the instrument panel flashes rapidly then ...

Page 64: ...e 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...

Page 65: ...ne with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is available to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owner...

Page 66: ...ervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to ...

Page 67: ...ean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate Item See Page Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Drive Belt Condition 83 I I I I Clutches 82 C C C Belt Tension I I I I Clutch Sheaves 82 I I I I ENGINE Engine Mounts I I I I Engine Torque Stop 82 I I I I Recoil Rope I I I I Cylinder Head Bolts I I I Cylinder Base Nu...

Page 68: ... FUEL MANAGEMENT Pilot Air Screws I I I Carburetor synchronize 75 I I I Idle RPM I I I Throttle Lever 44 I I I I I Oil Pump Lever synchronize I I I Choke I I I Vent Lines I I I I Fuel Lines 74 I I I I Fuel Filter 74 R Every 2000 mi 3200 km or Every 2 years Oil Filter 73 R Oil Lines 73 I I I Air Box I I I I I Drain and Water Traps 76 I I I ELECTRICAL Auxiliary Shut Off Switch 48 I I I I I Throttle ...

Page 69: ...ion Shock Oil R Cooling System 74 I I I I Drive Shaft Bearing 69 L L L I Jackshaft Bearings 96 L L L I Skags Wear Bars 91 I I I I I Ski Saddle Spindle Bolts I I I I I Steering Arm s I Drive Chain Tension 77 I I I I I Hood and Side Panel Fasteners 68 I I I I I Rear Wheel Idler Bolts 87 I I I I I Idler Bolt Jam Nut 87 I I I I I Rear Suspension Pivot Shafts 69 L L L Camber Alignment I I I Handlebar C...

Page 70: ...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 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 aut...

Page 71: ...ions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the life of the suspension For more information about suspension lubrication and adjustments see your POLARIS dealer INDY Rear Suspension 144 Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel This should take a...

Page 72: ...n 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 T...

Page 73: ...ge too high will always cause engine dam age if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile See the specifications section beginning on page 98 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 ...

Page 74: ...the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 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 TIP Incorrect fuel mixture can often cause a spark plug to appear too dark o...

Page 75: ...ction Always reinstall the intake filters before operating the snowmobile Fuel Pump All fuel pump service must be performed by an authorized POLARIS dealer Do not attempt to service the fuel pump Oil Lines Inspect oil line condition every 1000 miles 1600 km Oil Filter The oil filter is located in line between the oil tank and oil pump Have your dealer change the oil filter and bleed the system at ...

Page 76: ...Replace worn or damaged fuel lines promptly 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 Cooling System Inspect the fan intake and outlet ducts for cracks blockage obstructions damaged seals or loosening of the ducts Make any necessary repairs promptly Exhaust System Check ...

Page 77: ... engine damage Have your POLARIS dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or balanced is important Properly adjusted carburetors can greatly improve engine performance fuel economy engine life and reliability If you notice any of the following conditions the carburetor may n...

Page 78: ...ur Always work in a well ventilated area away from anything that may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the fuel warnings on page 54 Cleaning Procedure 1 Turn the fuel valve off 2 Place a container or shop towels below the plug to catch drained fuel 3 Slide the clamp 1 away from the drain plug 2 and remove the drain plug from the sedime...

Page 79: ... 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 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 Jam Nut Adjuster Bolt ...

Page 80: ...brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 inch or 1 5 mm Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thickness is less than 1 16 inch or 1 5 mm 4 Anti rattle springs come...

Page 81: ...ake 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 ...

Page 82: ...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 valv...

Page 83: ... hood 2 Remove the wire harness connector from the back of the headlight 3 Grasp the bulb housing and turn it counter clockwise to remove the bulb 4 Apply dielectric grease to the socket and install the new bulb Rotate the bulb 1 4 turn clockwise to secure it 5 Reinstall the connector to the back of the headlight 6 Reinstall the hood Taillight Brake Light Replacement The taillight assembly is not ...

Page 84: ...en made All clutch maintenance and repairs must be performed by an authorized POLARIS dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty NOTICE The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Torque Stop Periodically check torque stop cleara...

Page 85: ...y during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge 1 on the belt and apply downward pressure while measuring at point 2 This measurement should be 1 1 4 inches 3 2 cm Drive Belt Adjustment 1 L...

Page 86: ... forward engagement 4 Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch 5 Turn the wrench clockwise until the sheaves open far enough to remove the belt If the wrench does not turn readily rotate the driven clutch counter clockwise an additional 1 4 turn by hand and try again 6 Remove the belt from the driven clutch Drive Belt Inst...

Page 87: ... 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 oper...

Page 88: ...sion and alignment TIP Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the snowmobile and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel 4 Measure at the point where the weight is hanging TRACK TE...

Page 89: ...e equal adjustment on both sides of the track 9 Repeat the measurement on the other side of the track TIP Check more frequently when the snowmobile is new 10 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 11 Check track alignment see page 88 and adjust as necessary 12 Tighten the locknuts 13 Tighten the idler shaft bolts 14 T...

Page 90: ... Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track runs to the left loosen the idler shaft bolts then loosen the left locknut and tighten the left adjusting bolt If the track runs to the right loosen the idler shaft bolts then loosen the right locknut ...

Page 91: ...89 MAINTENANCE Steering System Steering Inspection Each week or before a long ride check all steering system fasteners and tighten if necessary ...

Page 92: ...ly 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 mi...

Page 93: ...eir original diameter TIP Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement 1 Raise and support the front of the snowmobile so the skis are approximately 6 inches 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse the steps to install a skag Rail Slide W...

Page 94: ...onnect the red positive battery cable last 4 Remove the battery Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 94 before installing the battery 1 Ensu...

Page 95: ...d during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charg...

Page 96: ... explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Tip Always verify battery condition before and 1 2 hours after the end of charging State of Charge Voltage Action Charge Time Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts N...

Page 97: ...obile requires preventive measures to aid against deterioration and to prolong the useful life of many components See page 100 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 pa...

Page 98: ...arings with POLARIS All Season Grease or a similar high quality grease to prevent corrosion Battery Maintenance Remove the battery and recharge it as outlined on page 94 Store the battery in a cool dry place 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...

Page 99: ...ith fogging oil Follow the instructions on the container 4 Allow the engine to stop by itself If stabilizer is not used drain the carburetors by removing the water trap drain plugs See page 76 TIP Jet restriction caused by improper storage can cause lean conditions and very poor slow speed driving quality Electrical Connections Replace worn or frayed electrical wire and connectors Be sure wiring h...

Page 100: ...Clutch CVTech PB50 CVTech Invance Reverse Transmission Electronic Reverse Engine and Cooling Engine EC550PM0130 Displacement 544 cc Cylinders 2 Bore x Stroke mm 73 0 x 65 0 Alternator Output 280 watt Carburetor Throttle Body 2 Mikuni Carburetor Model VM34 Idle RPM 1700 200 Rated Operating RPM 7000 200 Cooling Fan Air Ignition Type Kokusan 16 Bit ER Ignition Timing 15 BTDC 1600 RPM 17 BTDC 6500 RPM...

Page 101: ...165 160 155 150 150 Pilot Jet 45 45 45 45 45 45 45 45 Clip Position 4 3 3 2 2 1 1 1 3000 3700 10000 12000 Main Jet 170 160 155 150 150 145 140 140 Pilot Jet 45 45 45 45 45 45 45 45 Clip Position 4 3 2 2 1 1 1 1 550 INDY 144 Voyager Adventure LXT Clutching Chart ALTITUDE Meters Feet Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase Gearing Pitch Shaded cells ...

Page 102: ...icant qt 95 l 2873106 SCL Synthetic Chaincase Lubricant gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season 3 oz 89 ml 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT4 Brake Fluid 2872893 Engine Degreaser 2870505 Iso...

Page 103: ... drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for application Replace the drive belt Clutch alignment out of spec SEE YOUR DEALER Engine mount broken or loose Inspect and replace SEE YOUR DEALER Machine fails to move Clutch jammed Check for twisted belt or broken spring SEE YOUR DEALER Track jammed Foreign object may be caught or the rail slide melted...

Page 104: ...oor low RPM performance Worn drive belt Inspect and replace as needed Excessive belt sheave clearance SEE YOUR DEALER Sticky clutch SEE YOUR DEALER Engine doesn t turn Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inadequate fuel supply broken parts or improper cooling Hydrostatic lock Fuel may have entered the crankcase while the vehicle was standing or being transported S...

Page 105: ... necessary to change plug s Poor engine compression This indicates a major engine problem that must be repaired before operating SEE YOUR DEALER Engine lacks power Fouled or defective spark plug s Replace the plug s Fuel filter loss of high RPM power SEE YOUR DEALER Plugged fuel filter or tank pick up sock SEE YOUR DEALER Incorrect clutching SEE YOUR DEALER Carburetor and fuel pump SEE YOUR DEALER...

Page 106: ...o side Check ski alignment see page 90 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 Check rail slide replace if worn see page 91 Front end pushes Check for worn skags Check for binding front suspension shafts and steering components grease all pivot points elevate front of machine Increase...

Page 107: ...eratures 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 carburetor and choke synchronization fouled plugs debris in the carburetor s and water ice or dirt in the fuel tank or fuel line L...

Page 108: ...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 prov...

Page 109: ...es not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for purposes other than for which it was manufactured The warranty does not cover any damages that occur during trailer transit or as a result of unauthorized service or parts In add...

Page 110: ...o 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 y...

Page 111: ...overage in the event of a warranty claim 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 contamina...

Page 112: ... 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 ...

Page 113: ...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 warranty or service bulletin coverage of any kind other than safety bulletins Vehicles registered to Government officials or military personnel on assign...

Page 114: ...components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following...

Page 115: ...by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or ot...

Page 116: ...er each time your snowmobile is ser viced 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 ...

Page 117: ...115 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 118: ...116 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 119: ...nkage Care Storage 96 Coolant 74 Cooling System 74 Customer Service 106 D Disabled Operators 11 Display Units Standard Metric 33 Drive Belt Break In 52 Safety 19 Drive Belt Adjustment 83 Drive Belt Condition 83 Drive Belt Deflection 83 Drive Belt Installation 84 Drive Belt Removal 84 Drive Chain Tension 77 Driver Awareness 14 Driveshaft Bearing Lubrication 69 Driving Downhill 18 Driving in Hilly T...

Page 120: ...5 Low Oil Level 56 Lubrication 69 70 Lubrication Rear Suspension 69 M Maintenance Interval Table 65 67 Maintenance Program 64 Maintenance Recommendations 8 Maneuverability 15 Metric Display 33 N Noise 5 O Oil 55 56 Oil Change Chaincase 70 Oil Filter 73 Oil Injection System 52 Oil Level Chaincase 70 Oil Level Low 56 Oil Lines 73 Oil Recommendations 51 Operating in Deep Snow 17 Operation Warning 24 ...

Page 121: ...ion 11 Suspension Inspection Pre Ride 43 Suspension Lubrication Rear 69 Suspension Performance Tips 37 Switches Engine Stop Switch 58 Throttle Safety Switch 58 T Tachometer 33 Taillight Brakelight Replacement 81 Throttle Lever 59 Throttle Lever Inspection 44 Throttle Safety Switch 58 Throttle Safety Switch Inspection 44 Torque Stop 82 Towing 62 Track Alignment 88 Inspection 85 Lubrication 85 Tensi...

Page 122: ...For your nearest Polaris dealer call 1 800 POLARIS or visit www polaris com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9924266 Rev 01 Printed in USA PMS 419 9924266 ...