Polaris 600 INDY 2016, Owner'S Manual

Page 1: ...Snowmobile Owner s Manual for Maintenance and Safety 600 INDY 800 INDY ...

Page 2: ...he 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 For videos and more information about a safe riding experience with your Polaris vehicle scan this QR code with your smartphone ...

Page 3: ... 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 infor...

Page 4: ...ual 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 lan...

Page 5: ...and features The Perfect Fit 45 This section includes suspension set up information and explains how to make additional suspension adjustments for the perfect riding experi ence Pre Ride Inspections 55 This section explains procedures that must be performed before riding Operation 62 This section explains proper engine break in operation of features and general operating procedures Maintenance 74 ...

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Page 7: ... 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 Ma...

Page 8: ...hat 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...

Page 9: ...g 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 10: ...dous 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 in...

Page 11: ... 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 aerod...

Page 12: ...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 pr...

Page 13: ...r will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be pre...

Page 14: ...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 y...

Page 15: ... 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...

Page 16: ...lf 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 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 authoritie...

Page 17: ...now 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 Fo...

Page 18: ...erating 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 lubrica...

Page 19: ... 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 20: ...omplex 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 t...

Page 21: ...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 sn...

Page 22: ...93 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 2...

Page 23: ...rchase 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 c...

Page 24: ... 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 Machine stopped and engine at idle push yellow button on LH con trol to reverse Flashing light on dash in...

Page 25: ...ack Entanglement with the track or a fall from seat back may result in severe injury or death Hot Surface Warning WARNING Hot Surface Do Not Touch Burns may result Entire top of tunnel may be hot Install only accessories specifically approved for this model by POLARIS Track Warning Hot Surface Warning ...

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 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 ...

Page 27: ...ain 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...

Page 28: ...4 11 10 1 Nosepan 2 Skis 3 Front Bumper 4 Hood 5 Headlight 6 Windshield accessory 7 Handlebar 8 Fuel Filler Cap 9 Operator Seat 10 Taillight 11 Rear Bumper 12 Snow Flap 13 Suspension 14 Track 15 Side Panel 16 Side Panel Fasteners 16 15 8 ...

Page 29: ...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 MODE SET Switch 11 Headlight Dimmer Switch 12 Tool Kit Storage Bag 2 3 4 1 10 9 11 6 7 8 5 12 ...

Page 30: ...de 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 and exhaust sys...

Page 31: ... 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 MODE button until FUEL is displayed in the lower section of the gauge 4 Press and hold the SET switch on the left handlebar until the desired fuel type is displayed in the center of th...

Page 32: ...is 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...

Page 33: ...bile will not move when throttle is applied If you wish to use this system see page 36 of the Instrument Cluster section for security system activation and operating instructions Cause of DET Activation Solution Poor quality fuel 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 Refuel with recommende...

Page 34: ...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 35: ... See page 59 Low Oil The low oil indicator light may flicker at times due to oil movement in the bottle but when the light comes on and remains on while at idle add the recommended oil before further operation See page 68 Over Temperature This indicator illuminates to alert the opera tor that the engine is overheating The oper ator should take action to cool the engine See page 86 If the indicator...

Page 36: ...button or the MODE switch to toggle through the avail able modes Use the SET switch on the handlebar to save changes The information center is set to display standard units of measurement at the factory To change to metric see page 35 Information Display Area This area displays either engine speed engine temperature or maximum vehicle speed Odometer Engine Hour Display This area displays the odome...

Page 37: ...Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally Tip Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Fuel Selection Mode Wi...

Page 38: ...eature 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 ...

Page 39: ...ystem TASK 1 Activate the security system See your authorized POLARIS dealer to have the optional security system feature activated in the electronic control unit ECU TASK 2 Lock the System the First Time 1 Start the engine and lock the parking brake 2 Press and hold the MODE and SET buttons for 3 seconds then release SECURE OFF should be displayed If not repeat this step 3 Wait until ENTER displa...

Page 40: ...E The system is now unlocked 5 You must now enter a new security code Proceed immediately to TASK 4 TASK 4 Enter Your New Security Code 1 Immediately after locking and unlocking the system and while SECURE OFF is displayed press and release the MODE button to bring up the ENTER screen 2 When ENTER displays use the SET and MODE buttons to select and accept each digit of a new personal security code...

Page 41: ...rst digit of your security code is displayed press and release MODE to accept the digit TIP If the ENTER screen exits due to inactivity repeat step 2 4 Continue to use SET and MODE to select and accept the remaining two digits of the code 5 After accepting the third digit view the dis play screen SECURE ON displays if the system locks Engine speed is now limited and the snowmobile cannot be driven...

Page 42: ...he first digit of your security code is displayed press and release MODE to accept the digit TIP When the system is locked and engine temperature is above 120 F 49 C the correct password must be entered within 60 seconds or the engine will shut down 2 Continue to use SET and MODE to select and accept the remaining two digits of the code 3 After accepting the third digit view the dis play screen SE...

Page 43: ... code Security System Access Quick Reference Now that you have become familiar with the procedure for locking and unlocking the system use the chart below as a quick reference Security System Access Quick Reference Chart Action Result Start engine Lock parking brake Press and hold both MODE SET Displays ENTER to lock the system Press SET Advances a digit on the ENTER screen Press MODE Accepts a di...

Page 44: ...and release the MODE button or MODE switch to toggle to the diagnostic display mode If a code exists two numbers will appear in the display see illustration The check engine indicator will begin to flash 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 code Repeat until all codes are retrieved 5 Press and release the MODE butt...

Page 45: ...to the electronic control unit is shorted to a wire at battery voltage Diagnostic Codes Component Condition SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 4 Abnormal Rate of Change 10 Vehicle Speed Sensor Data Erratic Intermittent or Missing 84 2 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 4 Barometric Pressure Sensor Voltage Too High 108 3 Voltage ...

Page 46: ...AG Maximum Detonation Correction Limit Reached 1352 0 Knock Above Critical Level 16 Knock Level Cylinder 2 PTO Maximum Detonation Correction Limit Reached 1353 0 Knock Above Critical Level 16 Sensor Supply Voltage 1 TPS TMAP Sensor Power Voltage Too Low 3509 4 Sensor Supply Voltage 2 Ground Speed Sensor Voltage Too Low 3510 4 ECU Output Supply Voltage 2 Injection Supply PWR Voltage Too High 3598 3...

Page 47: ...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 ...

Page 48: ...n 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 Shock Valving Some shocks can be revalved if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness Ple...

Page 49: ... position at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred setup These adjustments are easy to make involve very little time or effort and greatly affect the ride In deep snow a new rail slide will offer improved performance over worn rail slide It can also improve top speed When riding on ice or hard p...

Page 50: ...apsing the rear suspension With the rider seated measure the dis tance between the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y from X sag X Y If the measured sag is incorrect adjust the FRA position and or rear torsion spring preload Tip This is only an initial setup and final ...

Page 51: ...mer ride is desired See your dealer for more information Limiter Strap Position Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling If a rider prefers more ski pressure for improved steering performance adjustments can be made to the front limiter straps Tighten the straps to increase ski pressure Loosen the straps to reduce ski pressure 1 Remov...

Page 52: ...pension coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amount of indepen dence between the movement of the front torque arm and the rear torque arm When hitting a bump the front torque arm starts to compress The FRSS links that movement to the rear torque arm ...

Page 53: ...e arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performance An adjustment dot is located on the RRSS This dot is on the longest end of the scissor stop Rear Rear Scissor Stop RRSS Attributes Moving the RRSS to a higher position will have the following effects on the suspension...

Page 54: ... most trail riding conditions To decrease weight transfer under acceleration for improved corner ing rotate the RRSS to a higher position To increase weight transfer or ski lift during acceleration rotate the RRSS to a lower position Tip Your dealer can help you with initial setup and additional setup instruc tions to help you achieve your opti mum ride A scissor stop tool is also available from y...

Page 55: ...t 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 ...

Page 56: ... desired angle Be sure handlebars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine 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 Stret...

Page 57: ...Level 85 Chaincase Oil Level 81 Injection Oil Level 68 Parking Brake Lock Brake Lever Brake System 58 59 90 Auxiliary Shut Off Switch Engine Stop Switch 61 Ignition Switch 61 Headlight Taillight Brakelight 61 Suspension Mounting Bolts 56 Skags Wear Bars 103 Ski Saddle and Spindle Bolts 56 Hood and Side Panel Fasteners 79 Throttle Lever Safety Switch 69 70 Rear Wheel Idler Bolts 99 Tether Switch St...

Page 58: ...ing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 99 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 103 Track Tension 98 All rear suspension components Lubrication 80 Ski runner skag Con...

Page 59: ...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 60: ...cates low brake fluid level or air in the hydraulic system Refer to the brake bleeding information on page 92 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 91 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always ...

Page 61: ...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 62: ...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 63: ... 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 64: ... more than 1 4 inch 2 54 cm open while cranking the engine When the engine starts immediately release the throttle CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running NOTICE Operating the vehicle immediately after cold starting could cause engine damage Allow the engine to warm up for several minutes before operating the...

Page 65: ...RIS 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 cont...

Page 66: ...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 68 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 ...

Page 67: ...e 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 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 t...

Page 68: ...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 The engine exhaust from this product contains chemicals known...

Page 69: ...ed 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 deic...

Page 70: ...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 p...

Page 71: ...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 72: ...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 73: ...en the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your vehicle is clear 3 Push the yellow reverse button on the left hand control for one sec ond then release The engine will automatically reduce ...

Page 74: ...nd begin to rotate forward The light on the instru ment panel will shut off 3 Apply the throttle slowly to make sure the transmission is in for ward Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 69 for more information about the engine stop switch and throttle safety switch SYSTEM WHAT IT DOES Ignition Switch Interrupts ignit...

Page 75: ...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 76: ...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 avail able to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owne...

Page 77: ...ervals 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...

Page 78: ... See Page Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 94 I I I Drive Belt Condition 95 I I I I Clutches 94 C C C Belt Tension I I I I Clutch Sheaves 94 I I I I ENGINE COOLING Engine Mounts I I I I Recoil Rope I I I I Cylinder Head Bolts I I I Cylinder Base Nuts I I I Ignition Timing BTDC I I I VES System C C C I Coola...

Page 79: ...I I I Brake System 58 90 I Brake Fluid 91 I FUEL MANAGEMENT Idle RPM I I I Throttle Lever 70 I I I I I Oil Pump Lever synchronize I I I Throttle Position Sensor I I I Fuel Lines 84 I I I I Fuel Filter 84 R Every 2000 mi 3200 km or Every 2 years Oil Filter 84 R Oil Lines 84 I I I Air Box I I I I I ELECTRICAL Auxiliary Shut Off Switch 61 I I I I I Throttle Safety Switch 69 I I I I I Ignition Switch ...

Page 80: ...ering Fasteners I I I I C Suspension Shock Oil SP Models R Cooling Fins and Shroud I I I I Driveshaft Bearing 80 L L L I Skags Wear Bars 103 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 89 I I I I I Hood and Side Panel Fasteners 79 I I I I I Rear Wheel Idler Bolts 99 I I I I I Idler Bolt Jam Nut 99 I I I I I Camber Alignment I I I Handlebar Centering I Tether Switch and Strap 6...

Page 81: ...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 82: ... lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the life of the sus pension For more information about suspension lubrication and adjust ments see your POLARIS dealer INDY Rear Suspension 121 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 app...

Page 83: ...an 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 ...

Page 84: ...he intervals outlined in the Periodic Mainte nance Table beginning on page 75 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 i...

Page 85: ... 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 TIP The tip should not be white A white insulator ti...

Page 86: ...re 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...

Page 87: ...or maintenance or repair replace the coolant with fresh Antifreeze 50 50 Premix Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are Coolant bottle overflow tank Pressure cap Connecting hoses Always maintain the coolant level at or slightly above the FULL COLD mark on the coolant bottle when the engine is cold 1 Stop the engine 2 Open the r...

Page 88: ...t 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...

Page 89: ...t this time 5 Remove the bleed screw from the water outlet manifold and or the thermostat housing Allow the coolant to bleed through the system until it runs out the bleed holes Reinstall the bleed screw into the manifold 6 Add coolant to the coolant bottle to the maximum mark 7 Reinstall the side panel Always ensure that the hood and side panels are securely in place before starting the engine 8 ...

Page 90: ...ecting 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 79 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 ...

Page 91: ...o 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 92: ...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 93: ...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 94: ... 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 val...

Page 95: ...g the headlight assembly 2 Remove the wire harness connector from the back of the headlight 3 Grasp the bulb housing and turn it counter clockwise to remove the bulb 4 Apply dielectric grease to the socket and install the new bulb Rotate the bulb 1 4 turn clockwise to secure it 5 Reinstall the connector to the back of the headlight 6 Secure the foam shield Taillight Brake Light Replacement The tai...

Page 96: ...epairs 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 ali...

Page 97: ...ring extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge 1 on the belt and apply downward pres sure while measuring at point 2 This measurement should be 1 1 4 inches 3 2 cm Drive Belt Adjustment 1 Loos...

Page 98: ...e 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 Ins...

Page 99: ... 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 100: ...on 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 TENS...

Page 101: ... 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 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 100 and adjust as necessary 12 Tighten the locknuts 13 Tighten the idler shaft bolts 14 ...

Page 102: ...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 ...

Page 103: ...101 MAINTENANCE Steering System Steering Inspection Each week or before a long ride check all steering system fasteners and tighten if necessary x x x x ...

Page 104: ...hicle 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 misalig...

Page 105: ...eir orig inal 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 ...

Page 106: ...erformance Follow the battery charging instructions on page 105 before installing the battery 1 Ensure that the battery is fully charged 2 Set the battery in the battery holder 3 Connect and tighten the red positive cable first 4 Connect and tighten the black negative cable last 5 Verify that cables are properly routed 6 Reinstall the side panel Battery Storage Whenever the vehicle is not used for...

Page 107: ...arge the battery at 1 2 amps or less until the battery voltage is 12 8 or greater Tip When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the batt...

Page 108: ...ventive measures to aid against deterioration and to prolong the useful life of many components See page 112 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 ...

Page 109: ...iod 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 fu...

Page 110: ...ce 11 5 in 29 cm Drive Belt P N 3211122 Drive Clutch Type P 85 Driven Clutch Type Team LWT Reverse Transmission Electronic Reverse Engine and Cooling Engine S4948 6044 OI6G Displacement 599 cc Cylinders 2 Bore x Stroke mm 77 25 x 64 Alternator Output 400 watt Recommended Engine Oil VES Throttle Body 1204816 Throttle Body Bore Size 46mm Idle RPM 1700 200 Rated Operating RPM 8250 0 250 Cooling Liqui...

Page 111: ...WER 5135403 20 41 72 Pitch 3000 3600 10000 12000 10 AL 1321531 120 310 7043681 RED BLK 7043058 56 42 36 LWER 5135403 20 41 72 Pitch Clutching Chart ALTITUDE Meters Feet Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase Gearing Pitch Shaded cells indicate factory settings 0 600 0 2000 10 64 1321585 Black Green 7042083 RED BLK 7043058 56 42 36 LWER 5135403 22 ...

Page 112: ...in 29 cm Drive Belt P N 3211115 Drive Clutch Type P 85 Driven Clutch Type Team Lightweight Reverse Transmission Electronic Reverse Engine and Cooling Engine S4953 8044 OI8G Displacement 794 cc Cylinders 2 Monoblock Bore x Stroke mm 85 x 70 Alternator Output 400 watt Recommended Engine Oil VES Throttle Body 1204815 Throttle Body Bore Size 48mm Idle RPM 1700 200 Rated Operating RPM 8250 0 250 Coolin...

Page 113: ... 5135401 20 41 72 Pitch 3000 3600 10000 12000 10 58 1321588 140 330 7043342 RED BLK 7043058 64 42 36 LW 5135401 20 41 72 Pitch Clutching Chart ALTITUDE Meters Feet Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase Gearing Pitch Shaded cells indicate factory settings 0 600 0 2000 10 66 1321584 120 310 Black 7043681 RED BLK 7043058 64 42 36 LW 5135401 22 40 72...

Page 114: ...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 Coolant 2880514 Antifreeze 50 50 Premix qt 95 l 2880513 Antifreeze 50 50 Premix gal 3 8 l Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT4 Brake Fluid 28...

Page 115: ...e 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 melte...

Page 116: ...OUR DEALER Poor low RPM performance Worn drive belt Inspect and replace as needed Excessive belt sheave clearance SEE YOUR DEALER Sticky clutch SEE YOUR DEALER Poor fuel quality Use 87 91 octane fuel or higher Engine doesn t turn Seized engine 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 ...

Page 117: ...e 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 Engine continually backfires Faulty plug s Change plug s Fuel System Dirt or ice may be in the fuel system deicer should be added to non ethanol fuel at all ...

Page 118: ...ge 52 Machine darts from side to side Check ski alignment see page 102 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Set static sag see page 48 Check rail slide replace if worn see page 103 Install Accu Trak dual skags see your dealer Front end pushes Check for worn skags Check for binding ...

Page 119: ...void 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...

Page 120: ...n 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 t...

Page 121: ...ed by POLARIS including but not limited to Two year extended engine coverage Two year powertrain coverage Extended service contract See your dealer for details and separate terms and conditions for any promotional warranties Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this regi...

Page 122: ... components use of aftermarket components unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty excludes damages or ...

Page 123: ... AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EX...

Page 124: ...the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be...

Page 125: ...utside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warra...

Page 126: ...components of systems if their only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This Emissions Limited Warranty does not cover components if their failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the fol...

Page 127: ... or workmanship This Limited Warranty does not cover damage due to accidents abuse or improper handling maintenance or use This Limited Warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This Limited Warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyo...

Page 128: ...er 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 ...

Page 129: ...127 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 130: ...Disabled Operators 12 Display Units Standard Metric 35 D Drive Belt Break In 64 Safety 18 Drive Belt Adjustment 95 Drive Belt Condition 95 Drive Belt Deflection 95 Drive Belt Installation 96 Drive Belt Removal 96 Drive Chain Tension 89 Driver Awareness 14 Driveshaft Bearing Lubrication 80 Driving Downhill 17 Driving in Hilly Terrain 17 Driving on Slippery Surfaces 16 Driving Responsibly 19 E Elect...

Page 131: ...vel 68 Lubrication Rear Suspension 80 M Maintenance Interval Table 76 78 Maintenance Program 75 Maintenance Recommendations 9 Maneuverability 18 Metric Display 35 N Noise 6 O Oil Change Chaincase 81 Oil Filter 84 Oil Injection System 64 Oil Level Chaincase 81 Oil Level Low 68 Oil Lines 84 Oil Recommendations 63 Operating in Deep Snow 16 Operation Warning 24 25 Operator Safety 8 20 Overheating Engi...

Page 132: ... Coupling 50 51 Suspension Inspection Pre Ride 56 Suspension Lubrication Rear 80 Suspension Performance Tips 47 Switches Engine Stop Switch 69 Ignition Switch 61 Mode Button 34 Mode Set Switch 34 Tether Switch 61 Throttle Safety Switch 69 T Tachometer 35 Taillight Brakelight Replacement 93 Tether Switch 61 Throttle Lever 70 Throttle Lever Inspection 57 Throttle Safety Switch 69 Throttle Safety Swi...

Page 133: ...For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Industries Inc 2100 Hwy 55 Medina MN 55340 Part No 9925069 Rev 01 Printed in USA 9925069 ...