Polaris 550 INDY 144 Owner'S Manual Download Page 41

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THE PERFECT FIT

Rear Suspension Adjustments

Rear Track Shock Spring

Adjust the rear track shock spring per the chart below.

REAR TRACK SHOCK SPRING (RTSS) SET-UP

(Standard Spring)

Measure spring length with suspension off the ground

Rider Weight

(including all

riders, gear, cargo,

& accessories)

Model

Installed Spring

Length

(rear suspension off the

ground)

Shaded cells indicate factory settings.

Lbs.

Inches

<160

<73

550 INDY Adventure/Voyageur/
LXT

11 1/8

28.2

550 INDY 144"

160-220

73-100 550 INDY Adventure/Voyageur/

LXT

10 3/4

27.3

550 INDY 144"

10 1/2

26.7

220-280 100-127 550 INDY Adventure/Voyageur/

LXT

10 1/2

26.7

550 INDY 144"

10 1/8

25.7

280-340 127-154 550 INDY Adventure/Voyageur/

LXT

10 1/8

25.7

550 INDY 144"

9 3/4

Maximum

Adjustment

24.7

Maximum

Adjustment

340-360 154-163 550 INDY Adventure/Voyageur/

LXT

9 7/8

Maximum

Adjustment

Maximum

Adjustment

Summary of Contents for 550 INDY 144

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

Page 2: ...e 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 rep...

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 pr...

Page 4: ...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 o...

Page 5: ...and features The Perfect Fit 34 This section includes suspension set up information and explains how to make additional suspension adjustments for the perfect riding experience Pre Ride Inspections 42...

Page 6: ...bile 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 necess...

Page 7: ...at snowmobiles conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered o...

Page 8: ...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 r...

Page 9: ...us 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...

Page 10: ...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 d...

Page 11: ...urn off the ignition open the side panels or hood make the adjustment secure shields and guards secure the side panels and hood and then restart the engine to check its operation WARNING Serious injur...

Page 12: ...r 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 shatterpro...

Page 13: ...n a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry su...

Page 14: ...ndles and running boards footrests 5 Make sure both driver and passenger are wearing appropriate riding gear including an approved helmet 6 Perform the recommended pre ride inspections See page 42 7 L...

Page 15: ...e driver 14 Make sure your passenger has read and understands the instructions and warnings in this manual 15 Never remove your hands from the handlebars while operating and always keep both feet on t...

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 ve...

Page 17: ...xtra caution Check headlight and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your snowmobile to a stop in the distance illu minated by the hea...

Page 18: ...snow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow...

Page 19: ...dequate 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...

Page 20: ...causing serious injury or death Use caution and good judgement when driving in hilly terrain Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low an...

Page 21: ...not attempt to service the clutches All clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynamically balanced before install...

Page 22: ...ll 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...

Page 23: ...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 W...

Page 24: ...ber is printed on the label Clutch Warning Belt Removal This warning label is found on the clutch cover WARNING Do not operate engine with hood or side panels open Do not attempt adjustment with engin...

Page 25: ...eds 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...

Page 26: ...eed 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 be...

Page 27: ...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...

Page 28: ...6 Windshield if equipped 7 Handlebar 8 Fuel Filler Cap 9 Operator Seat 10 Passenger Seat if equipped 11 Passenger Backrest if equipped 12 Cargo Rack if equipped 13 Taillight 14 Rear Bumper 15 Snow Fl...

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

Page 30: ...r grab handles can be adjusted for rider preference 1 Remove the hardware securing the grab handles to the grab handle tube 2 Reposition the grab handles to one of the three available positions and re...

Page 31: ...mobile 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 fo...

Page 32: ...oducts 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 spe...

Page 33: ...ion is in reverse See page 60 High Beam The high beam indicator illuminates when the lights are set to high beam Parking Brake This indicator illuminates when the parking brake is engaged It will also...

Page 34: ...h the vehicle powered by an external DC power supply connector The information center is set to display standard units of measurement at the factory To change to metric see page 33 Information Display...

Page 35: ...traveled by the vehicle if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center the trip meter displ...

Page 36: ...r to rider depending on rider weight vehicle speed riding style and trail conditions We recommend starting with factory settings and then customizing each adjustment individually to suit rider prefere...

Page 37: ...etainer and rotate it Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension Never exceed one inch 2 54 cm of preload beyond t...

Page 38: ...nts involve a compromise or trade off For example a suspension set up for snowcross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bottom out harshly on...

Page 39: ...mance over worn rail slide It can also improve top speed When riding on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are avai...

Page 40: ...snowmobile to remove the weight from the suspension 2 Use a tape measure to measure the spring installed length between the two spring retainers 3 Refer to the chart on page 39 to determine the corre...

Page 41: ...ension off the ground Shaded cells indicate factory settings Lbs kg Inches cm 160 73 550 INDY Adventure Voyageur LXT 11 1 8 28 2 550 INDY 144 160 220 73 100 550 INDY Adventure Voyageur LXT 10 3 4 27 3...

Page 42: ...Inspect skags frequently Worn skags may reduce steering and braking control on hard packed snow and ice Replace worn skags to maintain proper balance and vehicle control WARNING Loss of control can re...

Page 43: ...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 s...

Page 44: ...Chaincase Oil Level 70 Injection Oil Level 56 Parking Brake Lock Brake Lever Brake System 45 46 78 Auxiliary Shut Off Switch Engine Stop Switch 48 Ignition Switch 48 Headlight Taillight Brakelight 48...

Page 45: ...ing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 87 Rear idler adjusting bolt locknuts Tightness Torque arm bolt...

Page 46: ...l 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...

Page 47: ...tes low brake fluid level or air in the hydraulic system Refer to the brake bleeding information on page 80 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed chec...

Page 48: ...lace 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 br...

Page 49: ...G 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 trac...

Page 50: ...switch down to stop the engine Pull it up to allow restarting Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF Tether Switch if equipped If your snowmobile has a te...

Page 51: ...OTICE Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Damage may result 5 If equipped with electric start turn the key to START to crank the...

Page 52: ...e engine stop switch and throttle safety switch SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Choke Floods engine Half throttle or le...

Page 53: ...s 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...

Page 54: ...nded by POLARIS may cause serious engine damage We recommend the use of POLARIS lubricants for your vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels l...

Page 55: ...stand to securely support the rear of the snowmobile at the rear bumper The track should be about 4 inches 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depre...

Page 56: ...or death in a short time Turn the fuel valve off whenever the snowmobile is stored parked or transported The engine exhaust from this product contains chemicals known to cause cancer birth defects or...

Page 57: ...up to 10 ethanol sometimes labeled oxygenated do not add deicers or additives that contain any form of alcohol Fuel Valve The fuel valve is located near the lower rear area of the oil bottle Turn the...

Page 58: ...ded replacement parts Carburetion NOTICE Making non recommended adjustments could result in vehicle or engine damage as well as denial of warranty claims We recommend that all carburetor adjustments b...

Page 59: ...stalled in produc tion is not correct for all altitudes and or temperatures See page 75 for more information NOTICE A main jet that s too small will cause a lean operating condition and may cause seri...

Page 60: ...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 do...

Page 61: ...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 servic...

Page 62: ...g the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running 1 Stop the snowmobile and...

Page 63: ...instrument panel will shut off 3 Apply the throttle slowly to make sure the transmission is in forward High Altitude Setting At altitudes above 6000 feet 1800 m the engine will require a different ign...

Page 64: ...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 t...

Page 65: ...e 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 66: ...rvals 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...

Page 67: ...an adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate Item See Page Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Drive Belt Conditio...

Page 68: ...Fluid 79 I FUEL MANAGEMENT Carburetor synchronize 75 I I I Idle RPM I I I Throttle Lever 44 I I I I I Oil Pump Lever synchronize I I I Choke I I I Vent Lines I I I I Fuel Lines 74 I I I I Fuel Filter...

Page 69: ...eners I I I I I Steering Fasteners I I I I C Cooling System 74 I I I I Skags Wear Bars 91 I I I I I Ski Saddle Spindle Bolts I I I I I Steering Arm s I Drive Chain Tension 77 I I I I I Hood and Side P...

Page 70: ...lace 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 ope...

Page 71: ...iodic Maintenance Table beginning on page 65 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your rid...

Page 72: ...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 drai...

Page 73: ...e too high will always cause engine dam age if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile See the specifica...

Page 74: ...he choke or incorrect carburetion adjustments Spark Plug Removal and Replacement Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the eng...

Page 75: ...tion Always reinstall the intake filters before operating the snowmobile Fuel Pump All fuel pump service must be performed by an authorized POLARIS dealer Do not attempt to service the fuel pump Oil L...

Page 76: ...ce worn or damaged fuel lines promptly NOTICE Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked rep...

Page 77: ...engine damage Have your POLARIS dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or...

Page 78: ...r Always work in a well ventilated area away from anything that may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the fuel warnings on page 54 Cleani...

Page 79: ...the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 3 Loosen the adjuster bolt jam nut 4 Finger tighten the adjuster bolt until it can no longer be adjusted b...

Page 80: ...rakes 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 th...

Page 81: ...ke 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 o...

Page 82: ...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...

Page 83: ...hood 2 Remove the wire harness connector from the back of the headlight 3 Grasp the bulb housing and turn it counter clockwise to remove the bulb 4 Apply dielectric grease to the socket and install th...

Page 84: ...n 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...

Page 85: ...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...

Page 86: ...forward engagement 4 Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch 5 Turn the wrench clockwise until the sheaves open far enough...

Page 87: ...needs snow for lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear WARNING Operating with i...

Page 88: ...ion 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 Pla...

Page 89: ...equal adjustment on both sides of the track 9 Repeat the measurement on the other side of the track TIP Check more frequently when the snowmobile is new 10 Start the engine and slowly rotate the trac...

Page 90: ...Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track ru...

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

Page 92: ...ur POLARIS dealer The skis on your snowmobile are set with a small amount of toe out at the factory You can inspect the toe setting by following the procedure below If adjustments are required refer t...

Page 93: ...ir 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 inche...

Page 94: ...nnect the red positive battery cable last 4 Remove the battery Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not...

Page 95: ...ng the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the install...

Page 96: ...explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Tip Always verify bat...

Page 97: ...bile requires preventive measures to aid against deterioration and to prolong the useful life of many components See page 100 for the part numbers of POLARIS products Cleaning and Preservation Proper...

Page 98: ...ing on page 65 Battery Maintenance Remove the battery and recharge it as outlined on page 94 Store the battery in a cool dry place Clutch and Drive System Remove the drive belt and store in a cool dry...

Page 99: ...th fogging oil Follow the instructions on the container 4 Allow the engine to stop by itself If stabilizer is not used drain the carburetors by removing the water trap drain plugs See page 76 TIP Jet...

Page 100: ...lutch Driven Clutch CVTech PB50 CVTech Invance Reverse Transmission Electronic Reverse Engine and Cooling Engine EC550PM0131 Displacement 544 cc Cylinders 2 Bore x Stroke mm 73 0 x 65 0 Alternator Out...

Page 101: ...65 160 155 150 150 Pilot Jet 45 45 45 45 45 45 45 45 Clip Position 4 3 3 2 2 1 1 1 3000 3700 10000 12000 Main Jet 170 160 155 150 150 145 140 140 Pilot Jet 45 45 45 45 45 45 45 45 Clip Position 4 3 2...

Page 102: ...873105 SCL Synthetic Chaincase Lubricant qt 95 l 2873106 SCL Synthetic Chaincase Lubricant gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season 3 oz 89 ml 2871322 All Season Greas...

Page 103: ...drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for application Replace the drive belt Clutch alignment out of spec SEE YOUR DEALER Engine mount broken or l...

Page 104: ...or low RPM performance Worn drive belt Inspect and replace as needed Excessive belt sheave clearance SEE YOUR DEALER Sticky clutch SEE YOUR DEALER Engine doesn t turn Seized engine SEE YOUR DEALER Sei...

Page 105: ...necessary to change plug s Poor engine compression This indicates a major engine problem that must be repaired before operating SEE YOUR DEALER Engine lacks power Fouled or defective spark plug s Repl...

Page 106: ...r dealer for ski alignment inspection Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Check r...

Page 107: ...ratures 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 Br...

Page 108: ...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 informati...

Page 109: ...d 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...

Page 110: ...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 pur...

Page 111: ...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 I...

Page 112: ...he 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 coun...

Page 113: ...tside 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 s...

Page 114: ...omponents 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 Limite...

Page 115: ...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 structurall...

Page 116: ...r each time your snowmobile is ser viced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED...

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

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

Page 119: ...Coolant 74 Cooling System 74 Customer Service 106 D Disabled Operators 11 Display Units Standard Metric 33 Drive Belt Break In 52 Safety 19 Drive Belt Adjustment 83 Drive Belt Condition 83 Drive Belt...

Page 120: ...erval Table 65 67 Maintenance Program 64 Maintenance Recommendations 8 Maneuverability 15 Metric Display 33 N Noise 5 O Oil 55 56 Oil Change Chaincase 70 Oil Filter 73 Oil Level Chaincase 70 Oil Level...

Page 121: ...Engine Stop Switch 58 Handlebar Grip Warmer Switch 27 Headlight Dimmer Switch 27 Tether Switch 48 Throttle Safety Switch 58 Thumbwarmer Switch 27 T Tachometer 33 Taillight Brake Light Replacement 81 T...

Page 122: ...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 9925097 Rev 02 Printed in USA 9925097...

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