Polaris 600 INDY SP 2019, Owner'S Manual

Page 1: ...2019 Owner s MAnual 800 INDY XC 129 600 INDY XC 129 600 INDY SP ...

Page 2: ...ne expect as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious ...

Page 3: ...2019 Owner s Manual 800 INDY XC 129 ES 600 INDY SP 129 ES 600 INDY XC 129 SC Select 800 INDY XC 129 SC Select 600 INDY XC 129 ES INTL SC ...

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

Page 5: ...biles SPORTSMAN All terrain vehicles Low emission vehicles LEVs RANGER utility vehicles BRUTUS work vehicles SLINGSHOT three wheel motorcycles RZR sport vehicles GEM vehicles INDIAN motorcycles POLARIS POWER generators POLARIS DEFENSE combat vehicles Timbersled Snow Bikes For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual ...

Page 6: ...serious injury CAUTION SAFETY ALERT CAUTION indicates a hazardous situation which if not avoided COULD result in minor to moderate injury CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components NOTICE NOTICE provides key information by clarifying i...

Page 7: ...roduction 7 Safety 11 Features 31 Gauge 41 The Perfect Fit 65 Pre Ride Inspections 81 Operation 87 Maintenance 97 Specifications 139 Troubleshooting 149 Warranty 159 Maintenance Log 169 5 TABLE OF CONTENTS ...

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Page 9: ... intervals This service can be performed by your authorized POLARIS dealer 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 ...

Page 10: ... conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter machines we ask ...

Page 11: ... tunnel certification tunnel VIN or emissions certification labels with the wrap If the tunnel wrap doesn t provide an opening for these labels remove the section of wrap where the labels are located q Certification Label w Tunnel VIN e Emission Certification Label VEHICLE MODEL NUMBER TUNNEL VIN RIGHT SIDE OF TUNNEL ENGINE SERIAL NUMBER ON RECOIL HOUSING KEY NUMBER 9 INTRODUCTION ...

Page 12: ...TION The ignition keys are etched with an identification number Remove the spare key and store it in a safe place Your key can be duplicated only by mating a POLARIS key blank using the same identification number with one of your existing keys so if both keys are lost the ignition switch assembly must be replaced 10 INTRODUCTION ...

Page 13: ... snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All POLARIS snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile ma...

Page 14: ...then restart the engine to check its operation WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments RIDING POSITION Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience and the features available on some snowmobiles but under many conditions the pro...

Page 15: ...onsists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label 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 recommend...

Page 16: ... you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the conditions you may encounter Such equipment may include but is not limited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cellular telephone Always carry the...

Page 17: ...tance between posts Guy wires on utility poles are also difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your snowmobile will drown out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or highways Steep embankments may also hide your view Always leave yourself a wa...

Page 18: ...NING An avalanche can occur at any time in any conditions and on any slope The avalanche information provided in this manual should be considered basic information and is not intended to replace your participation in an avalanche safety training course After reviewing the avalanche information in this manual be sure to participate in an avalanche safety training course before riding in mountainous...

Page 19: ...ng in mountainous terrain A digital avalanche beacon with new fresh alkaline batteries An avalanche probe A compact shovel and hand saw A backpack preferably an avalanche air bag backpack Emergency provisions including the following items Small first aid kit Extra pair of gloves Extra dry socks Tow rope map compass GPS Lighter or waterproof matches Signal mirror and whistle Bottled water High calo...

Page 20: ... cotton materials which will freeze if they get wet Wear highly visible gear Try on all gear and equipment to make sure it fits and doesn t interfere with your riding capabilities Place all survival aids in your backpack and wear the backpack at all times Non essential items can be stored on the snowmobile in an accessory bag Read and follow the manufacturer s user and maintenance instructions for...

Page 21: ...nd under a snowpack Cracks across the top of a snowpack A recent heavy snowfall Blowing snow Rain Rapid warming GET OUT OF HARM S WAY Before riding always tell a responsible person i e at the lodge or gas station where your group is going Never ride alone Always ride in a small manageable group Riding in a large group makes it more difficult to track riders or find missing members Go one at a time...

Page 22: ...wind conditions Always review the user instructions provided with your safety equipment and follow the recommendations for maintenance testing and use Always test your safety equipment to ensure it works properly before riding in mountainous terrain Always store your survival gear in your backpack and wear the backpack Do not store your survival gear on the snowmobile Always research current avala...

Page 23: ...cautious route finding and conservative decision making essential Natural avalanches possible human triggered avalanches likely Small avalanches in many areas or large avalanches in specific areas or very large avalanches in isolated areas 2 Moderate Heightened avalanche conditions on specific terrain features Evaluate snow and terrain carefully identify features of concern Natural avalanches unli...

Page 24: ...y surfaces INADEQUATE SNOW CONDITIONS Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is a requirement for operation of your snowmobile NOTICE Driving in too little snow will result in excessive wear and damage to the slide rail track and or engine WARNING Inadequate cooling and lubrication will lead to ...

Page 25: ...njury or death Use caution and good judgement when driving in hilly terrain Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to ...

Page 26: ...that rotates at high speeds Each clutch is dynamically balanced before installation Any tampering may disrupt this precision balancing and create an unstable condition COLD WEATHER DRIVE AWAY Whenever your snowmobile has been parked for a length of time especially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough ...

Page 27: ...sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions Your snowmobile is not inte...

Page 28: ...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 WINDCHILL CHART C 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 29 32 36 39 43 46...

Page 29: ...el q is located below the steering post WARNING This vehicle is designed for operator only NO PASSENGER Fuel Recommended 91 Octane Without Ethanol For Maximum Performance See Decal On Left Hand Side Panel For Proper Gauge Setting REVERSE WARNING The Reverse Warning label w is located on either side of the operator seat WARNING Reverse operation even at low speeds can cause loss of control resultin...

Page 30: ... on the oil bottle WARNING Do not operate engine with hood or side panels open Do not attempt adjustment with engine running Do not operate engine with the clutch guard removed Never run engine with drive belt removed Never service clutches yourself Your dealer can perform this service BELT REMOVAL ALL UNITS 1 For electric reverse models engine must be stopped in forward to allow clutch opening 2 ...

Page 31: ... adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control the vehicle When operating on hard packed snow ice or when crossing roads steering and braking ability are gr...

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Page 33: ...q Skis i Operator Seat h Independent Front Suspension w Nosepan o Taillight j Side Panel e Front Bumper a Rear Bumper k Torsion Spring r Hood s Snow Flap l Rear Track Shock t Headlight d Upper Control Arm 1 Front Track Shock y Windshield accessory f Lower Control Arm 2 Rail u Handlebar g Spindle 31 FEATURES ...

Page 34: ...ck e Ignition Switch r Instrument Cluster t Engine Stop Switch y Throttle Control u Recoil Starter Handle i Handlebar Grip Warmer Switch o Thumb Warmer Switch a Electronic Reverse Button s Headlight Dimmer Switch d MODE SET Switch 32 FEATURES ...

Page 35: ... PIDD screen will turn off after several minutes of inactivity but if a battery is installed the PIDD will continue to draw a small amount of current from the battery until the key is turned off This feature is useful for accessing the PIDD without starting the engine but turn the key off when the PIDD is not in use The PIDD is not dependent on a battery while the engine is running but a battery i...

Page 36: ...e rider accessories require the use of an RCA power adapter If your model is not equipped with an RCA power plug on the handlebar cover an accessory 12 volt RCA adapter or RCA power plug can be purchased from your POLARIS dealer 12 VOLT RCA ADAPTER The RCA adapter can be used if your model is equipped with the 12 volt DC power receptacle Plug the adapter into the receptacle to convert it to a 12 v...

Page 37: ...der on the seat or tunnel floorboards 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 4 Start the engine Move the headlight switch to high beam 5 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm w below the mark on the wall 6 If adjustment is necessary access the headlight...

Page 38: ...lug or belt REPLACEMENT DRIVE BELT To insert a replacement drive belt into the spare drive belt container do the following 1 Rotate the spark plug wrench counter clockwise to release it from the bracket 2 Pull the wrench upward to remove it 3 Tilt the container until the bracket detaches from the bumper tube 4 Pull the container out of the compartment 5 When placing a drive belt into the container...

Page 39: ...TONATION PROTECTION MODES Check Engine LED Gauge Display Protection Mode 600 Models LED illuminated DETONATION displayed Slight drop in engine RPM power LED flashing DETONATION displayed Engine shut off 800 HO Models LED illuminated DETONATION displayed Slight drop in engine RPM power LED flashing DETONATION displayed Exhaust valves close to reduce engine RPM power Restart engine to reset The most...

Page 40: ...D screen changes to RED and the check engine temperature indicator e located on the top left of the screen illuminates when the engine is overheating Take action to cool the engine See page 39 The indicator will flash when engine temperature reaches critical levels Stop the engine immediately Please see your PIDD Owner s Manual for more information 600 800 HO MODELS ENGINE TEMPERATURE PROTECTION M...

Page 41: ...ontinue to operate while the indicator light is illuminated drive slowly and stop the engine frequently to allow it to cool down EXTENDED IDLE ENGINE SHUTOFF This engine feature causes the ECU to shut down the engine when engine temperature reaches 120 F 50 C and there is no throttle lever input for five minutes NOTE If equipped with an PIDD the gauge will remain on because the key is in the ON po...

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Page 43: ...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 The instrument cluster contains indicator lights and the rider information center The information center can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the MODE SET switch s on the Left Hand Control 41...

Page 44: ...oil movement in the bottle but when the light comes on and remains on add the recommended oil before further operation The low battery voltage indicator illuminates when the battery voltage is low The playback indicator illuminates when the gauge is in playback mode The low fuel indicator illuminates when fuel is low The high beam indicator illuminates when the lights are set to high beam The park...

Page 45: ...ea displays either engine speed or vehicle speed whichever is not displayed in the speed display engine temperature and maximum vehicle speed w Speed Display The speed display area displays either vehicle speed or engine speed e Fuel Gauge Not available on all models The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated ...

Page 46: ...peed or RPM To change the display press and release the MODE button or the MODE switch until the desired item is displayed ODOMETER ENGINE HOUR DISPLAY AREA This area displays the odometer Trip 1 meter Trip 2 meter CLOCK and Engine Hours meter The odometer displays the total distance traveled by the vehicle since manufacture Each trip meter records the distance traveled by the vehicle on a trip if...

Page 47: ...ons Menu 2 Press and release the MODE button until PLAYBACK appears in the information display area 3 Press and release the SET button RECORD will appear in the information display area 4 To begin recording Press and release the SET button The playback indicator will flash while recording is in progress Recording is complete when the light stops flashing NOTE To stop recording at any time during t...

Page 48: ...tton until PLAYBACK appears in the information display area 4 Press and release the SET button twice PLAY will appear in the information display area 5 Press and release the SET button to play the recorded data Once playback has concluded REPLAY will appear in the information display area 6 Press and release the SET button to REPLAY recorded data 7 Press and release the MODE button to end playback...

Page 49: ...ress and hold the center button on the instrument cluster to enter the Options Menu 2 Press and release the MODE button until engine temperature appears in the information display area 3 Press and release the SET button or SETswitch to change units Change Method 2 1 Press and release the SET button or SETswitch until the odometer appears in the information display area 2 Press and hold the SET but...

Page 50: ...n the following pages to have your system activated and to change the security code to one of your own choosing FIRST TIME USE OF YOUR SECURITY SYSTEM Perform all tasks in the order shown if you wish to activate and use the optional security system TASK 1 Activate the security system See your authorized POLARIS dealer to have the optional security system feature activated in the electronic control...

Page 51: ...ppear in the information display area 4 Press and release the SET button to increase the 1st digit 5 Press and hold the SET button to accept the 1st digit and advance to the 2nd digit 6 Press and release the SET button to increase the 2nd digit 49 GAUGE ...

Page 52: ... the SET button to accept the 3rd digit and submit code If code is correct SECURITY ON will appear in the information display area The system is now locked Proceed immediately to Task 3 If code is incorrect BAD CODE will appear in the information display area Return to step 3 to re enter code 50 GAUGE ...

Page 53: ...unning Press and release the SET button ENTER CO will appear in the information display area 2 Press and release the SET button to increase the 1st digit 3 Press and hold the SET button to accept the 1st digit and advance to the 2nd digit 4 Press and release the SET button to increase the 2nd digit 51 GAUGE ...

Page 54: ...d hold the SET button to accept the 3rd digit and submit code If code is correct SECURITY OFF will appear in the information display area NOTE The system is now unlocked If code is incorrect BAD CODE will appear in the information display area Return to step 1 to re enter code 8 You must now enter a new security code Proceed immediately to TASK 4 52 GAUGE ...

Page 55: ...ET buttons SET NEW CODE will appear on the information display area 2 Press and release the SET button to increase the 1st digit 3 Press and hold the SET button to accept the 1st digit and advance to the 2nd digit 4 Press and release the SET button to increase the 2nd digit 5 Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit 53 GAUGE ...

Page 56: ...system is NOT locked 8 Record your new security code in a safe place for future reference Record your new personal security code here __________________ TIP If you lose your personal security code see your dealer to have the code reset to 000 Then perform TASK 2 through TASK 4 to change the code to one of your own choosing LOCKING SYSTEM WITH PERSONAL SECURITY CODE 1 Start the engine 2 Press and h...

Page 57: ...ess and release the SET button ENTER CODE will appear in the information display area 5 Press and release the SET button to increase the 1st digit 6 Press and hold the SET button to accept the 1st digit and advance to the 2nd digit 7 Press and release the SET button to increase the 2nd digit 55 GAUGE ...

Page 58: ... the SET button to accept the 3rd digit and submit code If code is correct SECURITY ON will appear in the information display area The system is now locked Proceed immediately to Task 3 If code is incorrect BAD CODE will appear in the information display area Return to step 3 to re enter code 56 GAUGE ...

Page 59: ...in the information display area 2 Press and release the SET button to increase the 1st digit 3 Press and hold the SET button to accept the 1st digit and advance to the 2nd digit 4 Press and release the SET button to increase the 2nd digit 5 Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit 57 GAUGE ...

Page 60: ...the SET button to accept the 3rd digit and submit code If code is correct SECURITY OFF will appear in the information display area NOTE The system is now unlocked If code is incorrect BAD CODE will appear in the information display area Return to step 1 to re enter code 58 GAUGE ...

Page 61: ...a quick reference SECURITY SYSTEM ACCESS QUICK REFERENCE CHART Action Result 1 Start engine 2 Press and hold the center button 3 Press and release the SET button until SECURITY appears in information display area 4 Press and release SET button Displays ENTER CODE to lock the system Press and release the SET button Advances a digit on the ENTER CODE screen Press and hold the SET button Accepts a di...

Page 62: ... button on the instrument cluster to enter the Options Menu 3 Press and release the MODE button until DIAGCODE appears in the information display area The Diagnostic display mode will appear in the Options Menu if there is an active trouble code TIP When the diagnostic mode is displayed the check engine warning indicator will begin to flash 4 A set of two numbers will appear in the display The 2 6...

Page 63: ...Immediately clean off any gasoline that splashes on the instrument cluster NOTICE The speedometer may give wrong values at the existence of electromagnetic radiation 10 V m The PIDD also offers GPS mapping and Bluetooth connectivity for compatible smartphones devices This feature will display text messages and missed phone calls on the display screen The PIDD sub menus and most display features ar...

Page 64: ...PORTANT Whenever in doubt of your fuel purchase use the NON PREMIUM ETHANOL mode Use the following procedure to change the fuel type designation in the gauge Refer to the fuel type selection label located inside the left side panel 1 Start the engine 2 Press and hold the center button to enter the Options Menu 3 Press and release the MODE button until FUEL TYPE is displayed in the information disp...

Page 65: ...on to cool the engine See page 39 The indicator will flash when engine temperature reaches critical levels Stop the engine immediately OVERHEAT WARNING PIDD The engine temperature scale w located on the right side of the PIDD screen changes to RED and the check engine temperature indicator e located on the top left of the screen illuminates when the engine is overheating Take action to cool the en...

Page 66: ...GINE COOLING ACTIONS If the engine is overheating promptly take action to cool the engine Drive in loose snow View the coolant level Do not open the pressure cap while the engine is hot Add coolant if the level is low Stop the engine and allow it to cool down Ensure radiator is clean and free of debris NOTICE If you must continue to operate while the indicator light is illuminated drive slowly and...

Page 67: ...rack shock spring preload Step 3 Adjust shock clickers if equipped for ride quality For models equipped with monotube shocks always adjust the rear torsion spring preload to enhance bottoming resistance For models with shock clickers you can adjust the clickers to control bottoming and adjust ride comfort Turn a clicker counter clockwise to decrease damping for a softer ride Turn a clicker clockwi...

Page 68: ...nsion and at the front and rear track shock Make adjustments in 2 click increments then test ride When adjusting the front suspension always adjust both clickers equally To stop bottoming of the front or rear suspension stiffer ride rotate the clicker s clockwise two clicks as viewed from the top of the clicker then test ride Repeat the adjustment until bottoming stops and the desired ride quality...

Page 69: ...Different rate torsion springs are available if a firmer ride is desired See your dealer for more information NOTE Adding 1 1 seat or additional cargo may affect handling and require a spring rate change TORSION SPRING SETTING RECOMMENDED USAGE Low Rider s and gear 140 180lb If less than 140 use the optional spring chart for softer springs Medium Rider s and gear 180 220lb High Rider s and gear 22...

Page 70: ...PE DESCRIPTION 7043859 329 Spring Torsion LH Light Duty 7043860 329 Spring Torsion RH Light Duty 7045207 329 Spring Torsion LH Heavy Duty 7045208 329 Spring Torsion RH Heavy Duty 7045209 329 Spring Torsion LH Extra Heavy Duty 7045210 329 Spring Torsion RH Extra Heavy Duty REAR TRACK SHOCK FACTORY CLICKER SETTINGS MODEL FACTORY CLICKER SETTING FROM FULL STIFF Indy XC 5 68 THE PERFECT FIT ...

Page 71: ...h the shock at full extension NOTICE Never adjust spring preload to an installed length longer than the factory length or shorter than the minimum length as shown in the following chart Damage to the suspension could result When decreasing preload make sure at least two turns of preload are holding the retainer against the spring INDY SP INDY XC FRONT TRACK SHOCK SPRING SETTINGS FACTORY SPRING MAX...

Page 72: ...f clicks for each shock IFS SHOCK SPRING SETTINGS FACTORY SPRING FACTORY INSTALLED LENGTH MINIMUM INSTALLED LENGTH INDY SP 10 75 27 3 cm 10 25 4 cm INDY XC 10 25 4 cm 10 25 4 cm IFS REMOTE RESERVOIR SHOCK FACTORY CLICKER SETTINGS MODEL CLICKER SETTING FROM FULL HARD INDY SP N A INDY XC 12 CORNERING ADJUSTMENTS To improve cornering ability remove up to 1 2 of preload from factory IFS spring setting...

Page 73: ...osition q to maintain the optimum ride characteristics of the snowmobile Riders who desire less ski pressure and more weight transfer toward the rear of the snowmobile can lengthen the limiter strap by changing to position w 1 Loosen the lock nut 2 Adjust the limiter strap 3 Tighten the lock nut TORQUE 16 ft lbs 21 Nm 71 THE PERFECT FIT ...

Page 74: ...hand warmer brake switch wires when moving components COMPONENT TORQUE DO NOT OVER TIGHTEN q Left Handlebar Control Block 20 in lbs 2 3 Nm w Brake Lever Master Cylinder Torque the front screw first then torque the screw next to the reservoir 70 in lbs 7 9 Nm e Upper Lower Riser Clamps 14 8 ft lbs 20 Nm r Throttle Lever Block Set Screw 27 in lbs 3 1 Nm t Throttle Lever Block Cover Screws 6 in lbs 0...

Page 75: ...o the desired angle Be sure the handlebar brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when turned fully to the left or right If necessary loosen the set screws for the left and right controls rotate the controls slightly then tighten the set screws to the proper torque NOTICE Do not stretch wires while adjusting the contro...

Page 76: ...lts to 14 8 ft lbs 20 Nm ADJUSTABLE RISER IF EQUIPPED To adjust the riser if equipped do the following 1 Release the riser clamp q 2 Adjust the handlebar upward or downward to the desired height 3 Secure the riser clamp q Periodically inspect the torque of the upper lower handlebar clamp fasteners and slide fasteners TORQUE Handlebar Clamp Fastener Torque 16 ft lbs 21 Nm ROX Slide Fastener Torque ...

Page 77: ... avoid damaging hand warmer brake switch wires when moving components 2 Loosen the four left hand control mounting screws 3 Move the control block to the desired position NOTE If the control is loose and was inadvertently moved without loosening the screws move the control block slightly to the left or right to relocate the pins 75 THE PERFECT FIT ...

Page 78: ...light signal wire Tighten the clamp screws to specification beginning with the front screw first then the screw next to reservoir Do not over torque TORQUE 70 in lbs 7 9 Nm HANDLEBAR COMPONENTS Refer to the following illustration and measurements to position handlebar components at factory specified locations q 011 in 3 mm w 6 65 in 169 mm e 6 7 in 170 mm r 10 in 254 mm t 47 in 12 mm y 08 in 2 mm ...

Page 79: ...ation Do not over torque 4 With the engine off test throttle lever movement after tightening the screw See page 93 TORQUE 27 in lbs 3 Nm ENGINE STOP SWITCH ALIGNMENT CAUTION The stop switch must be positioned in an easily accessible location 1 Slightly loosen the set screw on the bottom of the housing w 2 Move the switch to the desired position 3 Tighten the screw to specification Do not over torq...

Page 80: ...ty Use only POLARIS approved traction products on your snowmobile See your dealer for more information about installing studs and or carbides CAUTION Failure to heed the following recommendations will result in tunnel or track damage Use of studs longer than the recommended length on snowmobiles equipped with center coolers will result in center cooler damage or damage to the tunnel Aggressive stu...

Page 81: ... 95 27 7 1 58 4 0 YES Signature Series 1 45 3 7 1 7 4 3 NO CARBIDE SKAGS A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain Use carbide skags with studded tracks to help maintain proper steering and control See page 126 Maintain a proper balance between the number of studs ...

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Page 83: ...vel page 92 Parking Brake Lock Brake Lever Brake System page 83 page 84 and page 114 Auxiliary Shut Off Switch Engine Stop Switch page 93 Ignition Switch page 33 Headlight Taillight Brakelight page 86 Suspension Mounting Bolts page 82 Skags Wear Bars page 126 Ski Saddle and Spindle Bolts page 82 Hood and Side Panel Fasteners page 106 Throttle Lever Safety Switch page 83 and page 83 Rear Wheel Idle...

Page 84: ...eekly basis or before any long trip ITEM SEE SECTION Check suspension mounting bolts for tightness Check rear idler wheel bolt for tightness page 121 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter strap condition Check rail slide condition page 127 Check track tension page 121 Check ski runner skag condition page 126 Check ski spindle bolts for tightness Chec...

Page 85: ...ls of your snowmobile Always make sure both are functioning properly Squeeze the throttle lever to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly or if you discover excessive lever freeplay DO NOTstart the engine Have the throttle serviced immediately THROTTL...

Page 86: ...e minutes or less 1 Brake Lever 2 Parking Brake Lever Lock 3 Master Cylinder Reservoir Cover LOCK ENGAGEMENT To engage the lock squeeze the brake lever tightly and push forward on the lock Hold the lock forward while releasing the brake lever NOTE If the brake lever is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break The parking brake light on the ...

Page 87: ...nterfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage TRACK Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty WARNING Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resultin...

Page 88: ... running Never start the engine without checking all vehicle components to be sure of proper operation See page 83 ENGINE STOP SWITCH Check the auxiliary shut off switch for proper operation Push the switch down to stop the engine Pull it up to allow restarting IGNITION SWITCH Make sure the engine stops when the ignition switch is turned to OFF TETHER SWITCH IF EQUIPPED If your snowmobile has a te...

Page 89: ...ile cranking the engine When the engine starts immediately release the throttle CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running NOTICE Operating the vehicle immediately after cold starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle If cold drive away is atte...

Page 90: ...t program The duration of these break in programs is independent of each other and is timed out based on engine run time Regardless of these automatic engine break in and enrichment features the following engine break in procedures must be performed when the engine is new or overhauled NOTE During this period of increased oiling sled performance will not be affected and you should ride normally BR...

Page 91: ...d levels lines and all other important areas of the snowmobile OIL INJECTION SYSTEM Always check and fill the oil bottle when refueling 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 your dealer can assist DRIVE BELT BREAK IN The break in period for a new drive belt is 30 miles 48...

Page 92: ...curely support the rear of the snowmobile at the rear bumper The track should be about 4 inches 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions TIP It will take longer to warm up the track sufficiently during colder outdoor temperatures 4 Release the throttle apply the brakes shut...

Page 93: ...consciousness or death in a short time WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas FUEL RECOMMENDATION For peak performance POLARIS recommends the use of 91 octane fuel or higher with no ethanol Although 87 octane fuel is usable some engine performance w...

Page 94: ...ght comes on 2 Open the left side panel 3 View the oil level in the oil bottle 4 Add oil as needed before operating NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refueling Add oil as needed The oil bottle cap is vented to allow proper oil flow Your POLARIS dealer can assist with recommended replacement parts ...

Page 95: ...sary to start the engine the throttle safety switch and engine stop switch may be disconnected from the wire harness When these switches are disconnected the ignition key switch must be used to shut off the engine DO NOTcontinue to operate the snowmobile with the throttle safety switch disconnected Return the snowmobile to an authorized POLARIS dealer for service as soon as possible ENGINE STOP SW...

Page 96: ... Apply a slight amount of throttle A properly functioning switch must shut down the engine POLARIS ELECTRONIC REVERSE CONTROL PERC WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed Shift to or from reverse only ...

Page 97: ...Stop the snowmobile and leave the engine idling CAUTION Engaging the starter when the engine is running WILL result in serious engine damage especially if the engine is in reverse Never engage the starter when the engine is running 2 Push the yellow reverse button for one second and release The engine will slow and begin to rotate forward The light on the instrument panel will shut off 3 Apply the...

Page 98: ...n the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in the towed object WARNING Braking distances increase when towing loads Slow down to maintain control of the snowmobile If the snowmobile becomes inoperable and must be ...

Page 99: ...stalled emissions information hangtag which is intended solely for your use in making a purchasing decision EMISSION CONTROL MAINTENANCE REQUIREMENTS Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specificat...

Page 100: ...uld be performed by a qualified service technician For continued optimum performance and component life continue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registered owner If during the course of the warranty period part failures occur as a result of owner n...

Page 101: ...elt Condition Ride Out Pre Ride Inspection I QUICKDRIVE Belt If Equipped I I I R I Drive Driven Clutch Condition I C I I C Drive Belt Tension I I I I Engine Engine Mounts I I I I Recoil Handle Rope Function I I I I Cylinder Head Bolts I I I Cylinder Base Nuts I I I Ignition Timing BTDC I I I Spark Plugs I I R I Exhaust Pipe I I Exhaust System Retaining Springs I I I I VES System 600 Engine Only C ...

Page 102: ...rical System Auxiliary Shut Off Pre Ride Inspection I Throttle Release Switch Pre Ride Inspection I Ignition Switch Pre Ride Inspection I Headlights Brake light Taillights Pre Ride Inspection I Hand Thumbwarmers Pre Ride Inspection I PERC Reverse System Pre Ride Inspection I Chassis Suspension Ski Toe Alignment I I I Front Rear Suspension Mounting Bolts Pre Ride Inspection Steering Fasteners Linka...

Page 103: ...t Track Tension I I I I I Front Limiter Strap I I I I I Rail Slide Condition I I I I I Rebuildable IFP Shock Oil R Rear Shock Threads L Bogie Wheel Condition Fastener Bolts I I I I I Rear Idler Wheel Bolts I I I I I Rear Idler Adjuster Bolt Jam Nuts I I I I I Cooling Fins and Shroud I I I I Camber Alignment I I I Handlebar Centering I Hood Seat Chassis Engine Compartment C C 101 MAINTENANCE ...

Page 104: ...dic Maintenance Table beginning on page 99 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the life of the suspension For more information about suspension lubrication and adjustments see your POLARIS dealer 102 MAINTENANCE ...

Page 105: ...c Chaincase Lube or equivalent product OIL LEVEL CHECK 1 Position the snowmobile on a level surface 2 Remove the fill plug 3 Using a funnel slowly add the recommended oil until the fluid begins to overflow 4 Clean the area with a clean dry shop towel Reinstall the fill plug TORQUE 4 4 9 ft lbs 5 4 6 6 Nm OIL CHANGE PUMP METHOD NOTE This procedure requires the use of a commercially available hand p...

Page 106: ...case 5 Lower the snowmobile 6 Using a funnel slowly add the recommended oil until the fluid begins to overflow Maximum fluid capacity is 10 5 oz 310 ml 7 Clean the area with a clean dry shop towel 8 Reinstall the fill plug TORQUE 4 4 9 ft lbs 5 4 6 6 Nm OIL CHANGE COVER DRAIN METHOD 1 Position the snowmobile on a level surface 2 Remove the two 2 screws securing the fender to the chaincase q 3 Remo...

Page 107: ...cover open NOTICE DO NOT insert a screwdriver or pry bar between the cover and chaincase Seal damage may occur 7 Allow the oil to drain completely 8 Tighten the cover screws w TORQUE 6 10 ft lbs 8 13 Nm 9 Remove the fill plug e Clean all metal shavings off the plug 105 MAINTENANCE ...

Page 108: ... 1000 miles 1600 km SIDE PANEL HOOD CAUTION The hood and side panels of the snowmobile protect the operator from moving parts Never operate a snowmobile with the hood or side panels open or removed Always ensure that the hood and side panels are securely in place before starting the engine SIDE PANELS To open a side panel rotate the two 1 4 turn fasteners at the upper edges of the side panel Relea...

Page 109: ...from the vehicle NOTE Store the hood in a position that will not damage the brake cooler duct INTAKE FILTERS The intake foam filters q limit snow ingestion into the intake system When operating in loose powder snow check the foam filters periodically to remove any accumulation of snow FUEL PUMP All fuel pump service must be performed by an authorized POLARIS dealer Do not attempt to service the fu...

Page 110: ...E 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 SPARK PLUGS SPARK PLUG RECOMMENDATIONS A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization Change ...

Page 111: ... A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the left side panel and hood 2 Remove the spark plug cap 3 Using the spark plug wrench provided in the tool kit rotate the spark plug counter clockwise to remove it 4 Reverse the procedure for spark plug installation Torque to specification 5 Reinstall the spark plug cap Verif...

Page 112: ...re that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every five 5 years and fresh Antifreeze 50 50 Premix Any time the cooling system has been drained for maintenance or repair replace the coolant with fresh Antifreeze 50 50 Premix COOLANT LEVEL The engine coolant level is controlled by the recovery system The recovery system components...

Page 113: ...hen the engine is warm or hot Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part NOTICE Severe engine damage may occur if the cooling system becomes restricted or plugged or contains trapped air pockets Perform this procedure in a well ventilated area Use the recommended coolant S...

Page 114: ...ated position 8 Lock the parking brake 9 Start the engine and allow it to run at a fast idle for several minutes until the heaters are warm to the touch Loosen the bleed screw occasionally to purge any trapped air 10 When all heater extrusions are warm to the touch stop the engine 11 Allow the engine and cooling system to cool Secure the bleed screw 12 Fill the coolant bottle to the COLD FILL mark...

Page 115: ...s and remove the hood 2 Inspect the muffler and pipes for cracks or damage 3 Check for weak or missing retaining springs or damper support grommets 4 Check for loose clamps on the pipe covers 5 Reinstall the hood and side panels DRIVE CHAIN TENSION Check drive chain tension weekly and before each long trip 1 Remove the side panels 2 Rotate the driven clutch counter clockwise to move all chain slac...

Page 116: ...ner than the backing plate approximately 1 16 inch or 1 5 mm A kit is available for replacing brake pads Your POLARIS dealer can assist WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake p...

Page 117: ...s with POLARIS DOT 4 high temperature brake fluid or an equivalent product WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of acci...

Page 118: ... cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 inch 6 8 cm below the lip of the reservoir opening Reinstall the gasket and cover 3 Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the...

Page 119: ... KEY ON power supplies battery voltage to the IDD and GPS puck If the IDD does not turn on when the key is in the ON position check for a blown fuse If the fuse is blown inspect the constant power circuit Repair or replace any damaged components before replacing the fuse CLUTCH SYSTEM Periodically inspect clutch sheaves for damage wear or belt residue To maintain optimum performance clean with non...

Page 120: ...ntate the belt to match the profile of the hood For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile DRIVE BELT DEFLECTION Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge on the belt and apply downward pressure while measuring at point This m...

Page 121: ...6 Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves open far enough to remove the belt If the wrench does not turn readily rotate the driven clutch counter clockwise an additional 1 4 turn by hand and try again 8 Remove the belt from the driven clutch DRIVE BELT INSTALLATION 1 With the ...

Page 122: ... to come off the snowmobile which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power NOTE The figures below are for reference only Your model may differ slightly 1 Using a hoist safely lift and support the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire l...

Page 123: ...damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty TRACK TENSION Track adjustment is critical for proper handling Always maintain correct tension and alignment TRACK TENSION DATA CHART SUSPENSION SLACK MEASUREMENT WEIGHT MEASUREMENT LOCATION INDY SP 7 8 1 1 8 inch 2 2 2 6 cm 10 lbs 4 54 kg 16 inches 40 cm ahead of rear idler shaft I...

Page 124: ...the track at least five revolutions Let the track come to a stop do not apply brakes 11 Check track alignment see page 122 and adjust as necessary 12 Tighten the locknuts 13 Tighten the idler shaft bolt TORQUE 35 ft lbs 47 5 Nm TRACK ALIGNMENT Periodically check that the track is centered and running evenly on the slide rails q Misalignment will cause excessive wear to the track and slide rail 1 S...

Page 125: ...djusting bolt 4 After adjustments are complete tighten the locknuts and torque the idler shaft bolt 55 ft lbs 75 Nm 5 Repeat steps 2 3 to verify proper alignment STEERING SYSTEM The steering systems on POLARIS snowmobiles can be adjusted with ski toe alignment Improper toe alignment can cause erratic steering Your dealer can assist with adjustments WARNING Improper alignment or adjustment may caus...

Page 126: ... or before a long ride check the following items If component damage or loose fasteners are found your POLARIS dealer can provide service q Ski Bolt Nuts w Tie Rod End Nuts e Upper Lower Control Arm Nuts All r Sway Bar Fasteners t Shock Mounting Fasteners y Lower Control Arm Spindle Nuts u Upper Control Arm Spindle Nuts i Ski Loop Rear Fasteners o Ski Loop Front Fasteners a Ski Skag Fasteners 124 ...

Page 127: ...ht compressing the suspension measure 10 inches 25 4 cm forward from the center of the ski mounting bolt see in illustration below At this point measure between the skis This is measurement q 3 Perform the same measurement rearward from the center of the ski mounting bolt This is measurement w 4 The q measurement should be 1 8 inch 3 mm greater than the w measurement If the skis are misaligned you...

Page 128: ...urning on hard packed snow or ice Check skags before each use of the snowmobile to ensure positive steering characteristics Skags must be replaced when worn to half their original diameter TIP Carbide skags must be replaced if any abnormal wear or chipping is found SKAG REPLACEMENT 1 Raise and support the front of the snowmobile so the skis are approximately 6 inches 15 2 cm from the ground 2 Remo...

Page 129: ...replaced when necessary For ease of inspection all POLARIS rail slides have a wear limit indicator groove w to indicate the minimum permissible slide thickness q Replace the rail slides if they are worn to the top of the groove at any point along their length Failure to do so may result in permanent damage to the track or rails 127 MAINTENANCE ...

Page 130: ... always connect the negative black cable last 1 Remove the right side panel to access the battery 2 Remove the two plastic rivets q securing the console panel to the chassis 3 Remove the plastic rivet w securing the fender to the chassis 4 Disconnect the black negative battery cable first 5 Disconnect the red positive battery cable last 6 Remove the battery hold down strap e 7 Remove the screw r s...

Page 131: ...ery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions before installing the battery See page 131 1 Ensure that the battery is fully charged 2 Set the battery in the battery holder 3 Place the battery shield on the battery bracket Install the screw to secure the shield TORQUE 7 ft lbs 10 Nm 4 Install the battery hold down strap 5 Connect an...

Page 132: ...ble B as shown in the image Both are routed up and over the rubber strap If the ground wires cable are routed down the side of the battery they may interfere with the rear side panel tab Note the routing of the RED positive battery cable C and that the right fender D is pulled away from the chassis Item E is the constant power fuse connector 7 Verify that cables are properly routed NOTICE Ensure t...

Page 133: ...nstallation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the b...

Page 134: ...ed slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours FALL TUNE UP For maximum performance your POLARIS dealer can perform a fall service tune up Their experienced and trained service tech...

Page 135: ...llowing 1 The rider should consume as much fuel in the fuel tank as possible during the last rides of the season 2 When performing the summerization storage procedures fill the fuel tank completely with non oxygenated fuel Note that most oxygenated fuels contain ethanol Since ethanol is hydroscopic oxygenated fuel will absorb a small amount of water vapor during the storage season and more so in h...

Page 136: ...on by sticking to the internal engine components including the spark plug electrodes Replace these spark plugs the following season after all of the fogging oil has been burned out of the engine DRIVE BELT STORAGE Never leave the drive belt installed in the clutches as oxidation may form where the belt contacts the aluminum clutch sheave faces To clean the drive and driven clutches do the followin...

Page 137: ...d make a note of the damage so that you and your authorized Polaris dealer can address the concern CHAINCASE Never leave used lubricant in the chaincase during the storage season Doing so may leave water present in the chaincase which may cause corrosion and rust 1 Follow the Owner s Manual procedures and drain fill the chaincase with new Polaris SCL Synthetic Chaincase Lubricant All Polaris PRO R...

Page 138: ...thin the engine compartment 4 Hand wash the exhaust system and dry the pipe and silencer with a clean shop towel 5 Apply spray metal protectant on exposed metal components such as the exhaust pipe silencer shock shafts and suspension springs pivots IMPORTANT Do not spray metal protectant on the drive or driven clutches LUBRICATE THE PIVOTS After washing the snowmobile it is important to use Polari...

Page 139: ...ater and allowed to air dry 3 If the snowmobile is equipped with electric start or a PIDD on board battery remove the battery from the battery tender and re install it back into the battery box Follow the owner s manual for battery installation procedures 4 Verify the spark plugs are installed and torqued Re install the spark plug wires NOTE Verify you hear an audible click when pushing the spark ...

Page 140: ...uired 15 Re start the engine and allow it ti run for another 15 minutes After 15 Minutes shutoff the engine and allow the exhaust pipe to cool 16 Remove and discard the spark plugs Install new spark plugs into the engine Obtain two more new spark plugs and install them into the spark plug holders or storage bag 17 Inspect the ski wear bars carbides Now is the time to replace the wear bars if damag...

Page 141: ...l Gearcase Oil Capacity N A Oil Capacity qts l 3 9 qts 3 7 l Height 46 inches 116 8 cm Length 117 inches 297 2 cm Designed Width 47 inches 119 cm Brake Type Hayes Phantom Floating Piston DOT 4 Drive Clutch Center Distance 10 625 inches 27 cm Drive Belt P N 3211165 Drive Clutch P 85 Driven Clutch Lightweight Team Roller Reverse Reverse Transmission Electronic Reverse 139 SPECIFICATIONS ...

Page 142: ...t Throttle Body 1204920 Recommended Engine Oil VES Throttle Body Bore Size 46 mm Idle RPM 1700 200 Rated Operating RPM 8250 0 250 Cooling Liquid Ignition Type CDI Ignition Timing BTDC 18 idle 1700 RPM w 120 F 49 C water temp Spark Plug Gap NGK BPR9ES 70 inches 027 mm Recommended Fuel Octane 91 recommended 87 minimum 140 SPECIFICATIONS ...

Page 143: ...ing in temperatures above 40 F 5 C Drive Clutch Bolt Torque 80 ft lbs 108 Nm Re torque after running engine 0 600 0 2000 10 64 140 330 7043829 Blk Purple 7043363 48 42 36 5140312 22 41 70 1 25 Rip II 1 352 Cobra 20 39 68 1 5 Storm 600 1200 2000 4000 10 62 1200 1800 4000 6000 10 60 1800 2400 6000 8000 10 58 2400 3000 8000 10 000 10 56 21 42 70 1 25 Rip II 1 352 Cobra 19 40 68 1 5 Storm 3000 3600 10...

Page 144: ...e Oil Capacity N A Oil Capacity qts l 3 9 qts 3 7 l Height 46 inches 116 8 cm Length 117 inches 297 2 cm Designed Width 47 inches 119 4 cm Brake Type Hayes Phantom Floating Piston DOT 4 Drive Clutch Center Distance 10 625 inches 27 cm Drive Belt P N 3211177 Drive Clutch P 85 Driven Clutch Lightweight Team Roller Reverse Reverse Transmission Electronic Reverse 142 SPECIFICATIONS ...

Page 145: ...t Throttle Body 1205241 Recommended Engine Oil VES Throttle Body Bore Size 46 mm Idle RPM 1700 200 Rated Operating RPM 8250 0 250 Cooling Liquid Ignition Type CDI Ignition Timing BTDC 18 idle 1700 RPM w 120 F 49 C water temp Spark Plug Gap BPR 9ES 027 inches 0 7 mm Recommended Fuel Octane 91 recommended 87 minimum 143 SPECIFICATIONS ...

Page 146: ...ive Clutch Bolt Torque 80 ft lbs 108 Nm Re torque after running engine 0 600 0 2000 10 66 GOLD 100 275 7041148 BLU BLK 123 203 7043064 58 44 36 5140311 23 37 68 1 25 Rip II 1 352 Cobra 22 41 70 1 5 Storm 600 1200 2000 4000 10 64 1200 1800 4000 6000 10 62 1800 2400 6000 8000 10 60 BLK 155 22 7043063 2400 3000 8000 10 000 140 330 7043829 21 42 70 1 25 Rip II 1 352 Cobra 19 40 68 1 5 Storm 3000 3600 ...

Page 147: ... Oil Capacity N A Oil Capacity qts l 3 9 qts 3 7 l Height 54 5 inches 138 4 cm Length 117 inches 297 2 cm Designed Width 47 inches 119 cm Brake Type Hayes Phantom Floating Piston DOT 4 Drive Clutch Center Distance 10 625 inches 27 cm Drive Belt P N 3211165 Drive Clutch P 85 Driven Clutch Lightweight Team Roller Reverse Reverse Transmission Electronic Reverse 145 SPECIFICATIONS ...

Page 148: ...t Throttle Body 1204920 Recommended Engine Oil VES Throttle Body Bore Size 46 mm Idle RPM 1700 200 Rated Operating RPM 8250 0 250 Cooling Liquid Ignition Type CDI Ignition Timing BTDC 18 idle 1700 RPM w 120 F 49 C water temp Spark Plug Gap NGK BPR9ES 70 inches 027 mm Recommended Fuel Octane 91 recommended 87 minimum 146 SPECIFICATIONS ...

Page 149: ...58 56 42 36 5135403 22 41 70 600 1200 2000 4000 10 62 1200 1800 4000 6000 10 60 1800 2400 6000 8000 10 58 2400 3000 8000 10 000 10 56 20 41 72 3000 3600 10 000 12 000 10A L Drive Clutch Bolt Torque 80 ft lbs 108Nm Re torque after running engine OPTIONAL USE 2 GRAM LIGHTER CLUTCH WEIGHTS WHEN OPERATING IN PROLONGED WARM TEMPERATURES LATE FALL SPRING SEASON TO MAINTAIN PEAK OPERATING RPM 147 SPECIFI...

Page 150: ...148 ...

Page 151: ...nce Your dealer can perform this service Drive belt turns over Wrong belt for application Replace the drive belt Clutch alignment out of spec Your dealer can perform this service Engine mount broken or loose Inspect and replace Your dealer can perform this service Machine fails to move Clutch jammed Check for twisted belt or broken spring Your dealer can perform this service Track jammed Foreign o...

Page 152: ...mance Worn drive belt Inspect and replace as needed Excessive belt sheave clearance Your dealer can perform this service Sticky clutch Your dealer can perform this service Poor fuel quality Use 87 91 octane fuel or higher Engine doesn t turn Seized engine Your dealer can perform this service Seizure is a result of poor lubrication inadequate fuel supply broken parts or improper cooling Hydrostatic...

Page 153: ...his indicates a major engine problem that must be repaired before operating Your dealer can perform this service Engine lacks power Fouled or defective spark plug s Replace the plug s Fuel filter loss of high RPM power Your dealer can perform this service Plugged fuel filter or tank pick up sock Your dealer can perform this service Incorrect clutching Your dealer can perform this service Engine co...

Page 154: ... PROBLEM SOLUTION Rear suspension bottoms too easily Refer to page 65 Revalve rear track shock see your dealer Rides too stiff in rear Refer to Check for binding suspension shafts and grease all pivot points Too much weight transfer when climbing Refer to page 65 Too little weight transfer when climbing Refer to page 65 Machine darts from side to side See your dealer for ski alignment inspection M...

Page 155: ...on Insufficient warm up Warm the engine at least five minutes Put the transmission in neutral to warm belt In extreme cold weather take the drive belt off the snowmobile and warm it up Break snowmobile loose from the snow Towing at low RPM Do not tow in deep snow Use fast aggressive throttle to engage clutch Riding with high RPM and slow speed 8000 RPM 10 MPH 16 km h Lower the gear ratio Reduce RP...

Page 156: ...ed fuel filter or tank pick up sock Your POLARIS dealer can perform service Alcohol based fuel additive used with Ethanol fuel Do not add deicers or additives that contain any form of alcohol while using up to 10 Ethanol fuel Improper engine modifications Do not modify the engine DIAGNOSTIC DISPLAY CODE DEFINITIONS Open Load There is a break in the wires that lead to the item listed in the chart i...

Page 157: ...erature Sensor Voltage Too High 110 3 Voltage Too Low 4 Temperature Too High 16 Engine Overheat Shutdown 0 Temperature Above Normal Range 15 Alternator Power Supply Potential DC Chassis Voltage Voltage Too High 167 3 Voltage Too Low 4 Exhaust Temperature Sensor Voltage Too High 173 3 Voltage Too Low 4 ECU Memory Checksum CRC Error 628 13 Injector 1 MAG Driver Circuit Open Grounded 651 5 Driver Cir...

Page 158: ...P 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 Voltage Too Low 4 Throttle Release Signal Voltage Too High 520194 3 Voltage Too Low 4 Throttle Stuck 7 Chassis Relay Driver Circuit Open Grounded 520208 5 Driver Circuit Short to B 3 Exhaust Valve Solenoid 600 Only Driver ...

Page 159: ... Signal Out of Range Valve Mid 520326 31 Signal Out of Range Valve Closed 520327 31 Short to Battery Voltage 520335 3 Short to Ground 4 Abnormal Transition 10 Electronic Oil Pump Driver Circuit Open Grounded 3589 4 Driver Circuit Grounded 5 Oil Pump or Fuel Injector Settings not Programmed Out of Calibration 520241 13 157 TROUBLESHOOTING ...

Page 160: ...158 ...

Page 161: ...anual Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following information 1 Serial number 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experienced 6 Length of time and conditions of operation 7 Previous correspondence Use the page provided near the front...

Page 162: ... including but not limited to Two year extended engine coverage Two year powertrain coverage Extended service contract See your dealer for details and separate terms and conditions for any promotional warranties REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this registration POLA...

Page 163: ...se of aftermarket components unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty excludes damages or failures caus...

Page 164: ...THERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO ...

Page 165: ...Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should wa...

Page 166: ... country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please wo...

Page 167: ... of vehicle travel or 30 calendar months from the date of purchase whichever comes first This Emissions Limited Warranty covers components if their failure increases the vehicle s regulated emissions and it covers components of systems if their only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This E...

Page 168: ...AT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so th...

Page 169: ...ends that you use only POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact POLARIS Customer Assistance United States ...

Page 170: ...168 ...

Page 171: ...ach time your snowmobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km 169 MAINTENANCE LOG ...

Page 172: ...DATE HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 170 MAINTENANCE LOG ...

Page 173: ... 142 Cold Weather Drive Away 24 Component Locations 31 Constant Power Fuse 117 Coolant 110 Coolant Level 110 Cooling System 110 Cooling System Bleeding 111 Cooling System Flushing 111 D Detonation Elimination Technology DET 37 154 Diagnostic Display Codes 154 Diagnostic Display Mode 60 Disabled Operators 16 Display Standard Metric 47 Drive Belt Adjustment 118 Condition 118 Deflection 118 Installat...

Page 174: ...ol Alignment Throttle 77 Hand Control Alignment Left 75 Hand Control Alignment Stop Switch 77 Handlebar Angle 73 Handlebar Component Fasteners 72 Handlebar Components 76 Headlight Adjustment 35 Helmet 13 Hood Access 106 Hood Fasteners 86 Hood Latches 86 I IFS Shock Factory Clicker Settings 70 IFS Shock Spring Settings 70 Ignition Lock System 48 Ignition Switch 33 86 Inadequate Snow Conditions 22 I...

Page 175: ...86 Recommended Maintenance 98 Registration 160 Restarting 87 Reverse Operation 94 95 Reverse Warning 27 Rider Capacity 12 Rider Information Center 43 Riding Apparel 13 14 Riding Position 12 Riser Angle 74 S Safety Labels 27 Safety Symbols 4 Security System 48 Shock Compression Damping 66 Shock Locations 66 Side Panel Access 106 Signal Words 4 Skags Carbide 79 Ski Alignment 125 Ski Skags 126 Slide ...

Page 176: ...fety Switch 93 Throttle Safety Switch Inspection 83 Tools 36 Towing 96 Track Alignment 122 Inspection 120 Lubrication 121 Tension 121 Track Inspection 85 Track Maintenance 120 Track Studding 78 Track Tension Data Chart 121 Track Warm Up 90 Track Warning 28 Transporting the Snowmobile 132 Treating the Fuel System 133 Troubleshooting Drive Belt 153 Troubleshooting Engine 149 Troubleshooting Suspensi...

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Page 178: ...For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Industries Inc 2100 Highway 55 Medina MN 55340 Part No 9928880 Rev 02 Printed in USA ...