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Polaris 600 INDY VOYAGEUR 2016, Owner'S Manual

The Polaris 600 INDY VOYAGEUR 2016 is a powerful and reliable snowmobile designed for adventure seekers. To ensure a smooth and hassle-free ownership experience, make sure to download the free Owner's Manual from manualshive.com, providing comprehensive instructions and maintenance details. Don't miss out on this essential manual for your Polaris 600 INDY VOYAGEUR 2016.

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98

MAINTENANCE

Clutch System

Periodically inspect clutch sheaves for damage, wear or belt residue. To 
maintain optimum performance, clean with non-oil based cleaners such 
as isopropyl alcohol. 

WARNING!

If you become aware of higher than normal clutch engagement or 

an unusual vibration or shift pattern, see your dealer immediately. Do not 
operate the snowmobile until repairs have been made. 

All clutch maintenance and repairs must be performed by an authorized 
POLARIS dealer. Any unauthorized modifications to clutches, such as 
adding or removing weights, will void the warranty.

NOTICE:

The bushings in the weights and rollers of POLARIS clutches are 
made of a material that may be damaged if lubricated. Do not 
lubricate clutch bushings.

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum 
performance. See your dealer for service and adjustments. A special tool 
is required to check for proper alignment.

Summary of Contents for 600 INDY VOYAGEUR 2016

Page 1: ...PMS 419 Snowmobile Owner s Manual for Maintenance and Safety 600 INDY VOYAGEUR ...

Page 2: ...ctions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For videos and more information about a safe riding experience with your Polaris vehicle scan ...

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

Page 4: ...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: ... and features The Perfect Fit 48 This section includes suspension set up information and explains how to make additional suspension adjustments for the perfect riding experience Pre Ride Inspections 55 This section explains procedures that must be performed before riding Operation 63 This section explains proper engine break in operation of features and general operating procedures Maintenance 76 ...

Page 6: ...4 ...

Page 7: ...are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding clubs When teaching inexperienced operators to ride set up a predetermined course for practice Mak...

Page 8: ...hat snowmobiles conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter m...

Page 9: ... wrap do not cover the 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 Vehicle Model Number ___________________________________________________ Tunnel VIN right side of tunnel ____________________________________________ Engine Serial Number on reco...

Page 10: ...ous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign ind...

Page 11: ...s in excellent operating condition at all times Always check major and vital safety components before every ride All POLARIS snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aero...

Page 12: ...Turn off the ignition open the side panels or hood make the adjustment secure shields and guards secure the side panels and hood and then restart the engine to check its operation WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments Riding Position Operating a snowmobile requires skill and balance for pro...

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

Page 14: ...e 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 owner s manual on yo...

Page 15: ... and speed limits Always be alert and pay attention to the trail ahead If your speed is 40 MPH 64 km h your snowmobile is traveling about 60 feet 18 m per second If you look back for only two seconds your snowmobile will travel about 120 feet 36 m If your speed is 60 MPH 96 km h your snowmobile will travel about 180 feet 55 m in two seconds Traveling at night requires extra caution Check headlight...

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

Page 17: ... snow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in mountainous terrain Before riding in mountainous terrain call or log on to your local avalanche advisory to get current weather and snow stability information Fo...

Page 18: ...erating on slippery surfaces Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is a requirement for operation of your snowmobile NOTICE Driving in too little snow will result in excessive wear and damage to the slide rail track and or engine WARNING Inadequate cooling and lubrica...

Page 19: ... causing serious injury or death Use caution and good judgement when driving in hilly terrain Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible roll over Slow down when reaching the crest of a hi...

Page 20: ... complex mechanism that rotates at high speeds Each clutch is dynamically balanced before installation Any tampering may disrupt this precision balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time especially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the th...

Page 21: ...ell as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions Your snow...

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

Page 23: ...LARIS at no charge The part number is printed on the label Clutch Warning WARNING Do not operate engine with hood or side panels open Do not attempt adjustment with engine running Do not operate engine with the clutch guard removed Never run engine with drive belt removed Never service clutches yourself See your dealer BELT REMOVAL ALL UNITS 1 For electric reverse models engine must be stopped in ...

Page 24: ...decal on left hand side panel for proper gauge setting 7178713 Reverse Warning WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric r...

Page 25: ...nglement with the track or a fall from seat back may result in severe injury or death 7172519 Hot Surface Warning WARNING Hot Surface Do Not Touch Burns may result Entire top of tunnel may be hot Install only accessories specifically approved for this model by POLARIS 7176164 Track Warning Hot Surface Warning ...

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

Page 27: ...ain vehicle control on ice or hard packed surfaces you should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for long periods Do not leave brake engaged for more than five minutes Before starting engine check throttle brake...

Page 28: ...kis 3 Front Bumper 4 Hood 5 Side Panel Strap 6 Headlight 7 Windshield if equipped 8 Handlebar 9 Operator Seat 10 Cargo Rack 11 Taillight 12 Rear Bumper 13 Receiver Hitch 14 Snow Flap 15 Suspension 16 Track 17 Side Panel 18 Side Panel Fasteners 17 10 13 5 18 ...

Page 29: ...op Switch 4 Instrument Cluster 5 Ignition Switch 6 Recoil Starter Handle 7 Brake Lever 8 Parking Brake Lock 9 Handlebar Grip Warmer Switch 10 Thumbwarmer Switch 11 Electronic Reverse Button 12 Mode Switch 13 Headlight Dimmer Switch 1 5 3 2 6 4 12 11 13 8 9 10 7 ...

Page 30: ...djust the beam downward Accessories POLARIS offers a wide range of accessories for your snowmobile to help make each ride more enjoyable Use only POLARIS parts and accessories on your POLARIS snowmobile 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 follow...

Page 31: ...your fuel purchase use the Eth setting as a safeguard Use the following procedure to change the fuel type designation in the gauge Refer to the fuel type selection label located inside the left side panel 1 Start the engine 2 Lock the parking brake 3 Press and release the SELECT button or SET switch until FUEL is displayed in the lower section of the gauge 4 Press and hold the SELECT button or SET...

Page 32: ...cases this is temporary and the operator does not need to take any action The engine will return to its normal performance automatically If severe detonation occurs the check engine light will begin to flash steadily and the gauge indicator will read dET see illustration The engine will enter a limp home mode and RPM will be limited to 6500 RPM The engine will remain in this mode until it is shut ...

Page 33: ...l not move when throttle is applied If you wish to use this system see page 39 of the Instrument Cluster section for security system activation and operating instructions Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol non ethanol fuel resistor installed Verify correct fuel resistor for fuel type in tank Low fuel no fuel in tank Refuel with rec...

Page 34: ... SET switch on the left handlebar NOTICE Certain products 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 Rider Information Center Check Engine Indicator High Beam Indicator Low Oil Indicator Over Temperature Indicator Park Brake Indicator Reverse Indicator MODE Button SELE...

Page 35: ... indicator flashes continued operation could result in serious engine damage Stop the engine immediately Low Oil Indicator The low oil indicator light may flicker at times due to oil movement in the bottle but when the light comes on and remains on add the recommended oil before further operation See page 70 High Beam Indicator The high beam indicator illuminates when the lights are set to high be...

Page 36: ...ettable trip meters 2 total engine hours of operation fuel level engine temperature and diagnostic display mode Setting changes must be made with the engine running or with the vehicle powered by an external DC power supply connector The information center is set to display standard units of measurement for distance and temperature To change to metric units see page 38 2 3 6 4 5 1 ...

Page 37: ... When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately Tip If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer 4 Odometer Engine Hour Display This area displays the odometer Trip A Trip B and engine hours To change the display see page 37 5 Battery Power This ind...

Page 38: ...isplays first make sure the information display area is set to display either engine speed or vehicle speed 2 Press and hold the mode button on the instrument cluster or the mode switch on the left handlebar for three seconds Information Display Area This area displays either engine speed or vehicle speed whichever is not displayed in the speed display engine temperature and maximum vehicle speed ...

Page 39: ... To reset a trip meter press and hold the SELECT button or the SET switch until the meter resets to zero Playback Function The playback function allows the rider to record and play back engine speed vehicle speed and throttle position sensor information for up to three minutes 1 To begin recording simultaneously press and hold the MODE and SELECT buttons on the instrument cluster for three seconds...

Page 40: ...s are changed The new settings will remain until changed by the operator Change Method 1 1 Press and release the MODE button or MODE switch until engine temperature displays 2 Press and hold the MODE button or MODE switch until the units change Change Method 2 1 Press and release the SELECT button or SET switch until the odometer displays 2 Press and hold the SELECT button or SET switch until the ...

Page 41: ...feature activated you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended A locked system will limit engine speed to 3000 RPM which prevents clutch engagement and the snowmobile will not move when throttle is applied If you wish to use this feature you must complete all four tasks on the following pages to have your system activated and to change the security c...

Page 42: ...ns for 3 seconds then release SECURE OFF should be displayed If not repeat this step 3 Wait until ENTER CODE displays then press and release SEL to advance the digit When 0 is displayed press and release MODE to accept the digit TIP If the ENTER CODE screen exits due to inactivity repeat step 2 4 Press and release SEL to advance the second digit When 0 is displayed press and release MODE to accept...

Page 43: ...m is now unlocked 5 You must now enter a new security code Proceed immediately to TASK 4 TASK 4 Enter Your New Security Code 1 Immediately after locking and unlocking the system and while SECURE OFF is displayed press and release the MODE button to bring up the ENTER CODE screen 2 When ENTER CODE displays use the SEL and MODE buttons to select and accept each digit of a new personal security code ...

Page 44: ...igit of your security code is displayed press and release MODE to accept the digit TIP If the ENTER CODE screen exits due to inactivity repeat step 2 4 Continue to use SEL and MODE to select and accept the remaining two digits of the code 5 After accepting the third digit view the display screen SECURE ON displays if the system locks Engine speed is now limited and the snowmobile cannot be driven ...

Page 45: ...hen the first digit of your security code is displayed press and release MODE to accept the digit TIP When the system is locked and engine temperature is above 120 F 49 C the correct password must be entered within 60 seconds or the engine will shut down 2 Continue to use SEL and MODE to select and accept the remaining two digits of the code 3 After accepting the third digit view the display scree...

Page 46: ...stem Access Quick Reference Now that you have become familiar with the procedure for locking and unlocking the system use the chart below as a quick reference Security System Access Quick Reference Chart Action Result Start engine Lock parking brake Press and hold both MODE SELECT SEL Displays ENTER CODE to lock the system Press SELECT SEL Advances a digit on the ENTER CODE screen Press MODE Accep...

Page 47: ...tive codes 1 Do not stop the engine 2 With the brake engaged press and release the SELECT button or SET switch to toggle to the diagnostic display mode When a code is active the diagnostic display mode will appear immediately following the engine hour display TIP When the diagnostic mode is displayed the check engine warning indicator will begin to flash 3 A set of two numbers will appear in the d...

Page 48: ...to the electronic control unit is shorted to a wire at battery voltage Diagnostic Codes Component Condition SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 4 Abnormal Rate of Change 10 Vehicle Speed Sensor Data Erratic Intermittent or Missing 84 2 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 4 Barometric Pressure Sensor Voltage Too High 108 3 Voltage ...

Page 49: ...AG Maximum Detonation Correction Limit Reached 1352 0 Knock Above Critical Level 16 Knock Level Cylinder 2 PTO Maximum Detonation Correction Limit Reached 1353 0 Knock Above Critical Level 16 Sensor Supply Voltage 1 TPS TMAP Sensor Power Voltage Too Low 3509 4 Sensor Supply Voltage 2 Ground Speed Sensor Voltage Too Low 3510 4 ECU Output Supply Voltage 2 Injection Supply PWR Voltage Too High 3598 3...

Page 50: ... from the shock and with the shock at full extension NOTICE Never adjust spring preload to an installed length longer than the maximum or shorter than the minimum lengths in the following chart Damage to the suspension could result Never exceed one inch 2 54 cm of preload beyond the factory settings When decreasing preload make sure at least two turns of preload are holding the retainer against th...

Page 51: ...e distance between the ground and the rear bumper at the exact loca tion used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measure ment Y from X Sag X Y Adjust sag by rotating the torsion spring preload cams located on the rear torque arm See illustration The ideal amount of sag for this rear suspension is five inches 12 7 cm X Y 5 in 12 7 cm If...

Page 52: ... Different rate torsion springs are available if a firmer ride is desired Contact your dealer for more information The following information is provided only as a guideline to be used for initial suspension set up Your set up may vary based on your desired riding style Soft long end of cam to front Medium short end of cam up Firm long end of cam up Soft Medium Firm ...

Page 53: ... the front suspension be sure the springs on both sides of the vehicle are at the same adjustment Always perform shock spring preload adjustments with the weight of the vehicle removed from the shock and with the shock at full extension NOTICE Never exceed one inch 2 54 cm of preload beyond the factory settings When decreasing preload make sure at least two turns of preload are holding the retaine...

Page 54: ...irst loosening its mounting screws set screws Take care to avoid damaging hand warmer brake switch wires when moving components 1 Left Hand Control Brake Master Cylinder 24 in lbs 2 7 Nm 2 Upper Lower Handlebar Clamps 16 ft lbs 21 6 Nm 3 Throttle Lever Block Set Screw 27 in lbs 3 Nm 4 Throttle Lever Block Cover Screws 6 in lbs 0 7 Nm 5 Auxiliary Engine Stop Switch Set Screw 12 in lbs 1 4 Nm 6 Rise...

Page 55: ...ck Alignment 1 Slightly loosen the set screw on the bottom of the housing 2 Move the control block to the desired position NOTICE Take care to avoid damaging hand warmer wires when moving components 3 Tighten the screw to specification Do not over torque Torque 27 in lbs 3 Nm 4 With the engine off test throttle lever movement after tightening the screw See page 72 Engine Stop Switch Alignment 1 Sl...

Page 56: ...on 1 Loosen the upper handlebar clamp screws 2 Adjust the handlebar forward or rearward to the desired position 3 Tighten the screws to specification Maintain an equal gap between the clamp and riser while tightening Do not over torque Torque 16 ft lbs 21 6 Nm Handlebar Angle 1 Loosen the lower riser clamp screws 2 Adjust the riser to the desired position 3 Tighten the screws to specification Main...

Page 57: ...89 Chaincase Oil Level 83 Injection Oil Level 70 Parking Brake Lock Brake Lever Brake System 58 59 94 Auxiliary Shut Off Switch Engine Stop Switch 62 Ignition Switch 62 Headlight Taillight Brakelight 62 Suspension Mounting Bolts 56 Skags Wear Bars 109 Ski Saddle and Spindle Bolts 56 Hood and Side Panel Fasteners 81 Throttle Lever Safety Switch 71 72 Rear Wheel Idler Bolts 105 Tether Switch Strap i...

Page 58: ...ms Check the following items on a weekly basis or before any long trip Item See Page Check suspension mounting bolts for tightness Check rear idler wheel bolts for tightness 105 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter strap condition Check rail slide condition 110 Check track tension 104 Check ski runner skag condition 109 Check ski spindle bolts for t...

Page 59: ...al Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience Throttle Lever The throttle and brake are the primary controls of your snowmobile Always make sure both are functioning properly Squeeze the throttle lever to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle posi...

Page 60: ...ates low brake fluid level or air in the hydraulic system Refer to the brake bleeding information on page 96 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 95 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always h...

Page 61: ...place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever ti...

Page 62: ...ure caused by operation on ice or poor lubrication conditions voids the track warranty WARNING Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle WARNING Use of traction products such as studs increases the possibility of track da...

Page 63: ...re that the hood and side panels are securely in place before starting the engine Seat Latches If your snowmobile is equipped with a removable seat ensure that the seat is properly installed and securely latched before each use of the snowmobile Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear i...

Page 64: ... switch down to stop the engine Pull it up to allow restarting Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF Tether Switch if equipped If your snowmobile has a tether switch remove the tether from the switch to make sure the engine stops immediately Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operat...

Page 65: ...en pull abruptly to crank the engine TIP Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Damage may result 5 If the engine does not start after several attempts slightly depress the throttle no more than 1 4 inch 2 54 cm open while cranking the engine When the engine starts immediately release the throttle CAUTION To avoid injury and or e...

Page 66: ...procedure If the engine fails to start using the normal procedure 1 Push the engine stop switch down to the OFF position 2 Turn the key to the OFF position 3 With both switches OFF squeeze and hold the throttle in the wide open position 4 Crank the engine several times to clear the engine 5 Release the throttle 6 Restart the engine using the normal starting procedure ...

Page 67: ...emical reactions can cause injection system blockage resulting in serious engine damage Oils may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All POLARIS oils are compatible with each other Initial Fuel Premix Always premix fuel in 5 gallon 19 liter increments in a separate fuel container Never add oil directly to the fuel tank O...

Page 68: ...tra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the snowmobile Oil Injection System Always check and fill the oil bottle when refueling See page 70 NOTICE Serious engine damage can occur without the proper lubrication Check the oil bottle level often during the first tank of fuel If the oil level doesn t go down contact your deal...

Page 69: ...e stand to securely support the rear of the snowmobile at the rear bumper The track should be about 4 inches 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions TIP It will take longer to warm up the track sufficiently during colder outdoor temperatures 4 Release the throttle apply th...

Page 70: ... in or near the area where refueling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time The engine exhaust from this product contains chemicals known...

Page 71: ...ded Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel Fuel System Deicers If you use non ethanol fuel sometimes labeled non oxygenated POLARIS recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline to prevent damage resulting from fuel system icing Never use dei...

Page 72: ...indicator light comes on 2 Open the left side panel 3 View the oil level in the oil bottle 4 Add oil as needed before operating NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refueling Add oil as needed The oil bottle cap is vented to allow proper oil flow See your POLARIS dealer for recommended replacement pa...

Page 73: ...y switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a carburetor throttle system malfunction immediately push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer Test the throttle safety switch system daily before operation 1 Sit on the seat 2 Start...

Page 74: ...f the throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 If the engine doesn t start take the snowmobile to an authorized POLARIS dealer for service Excessive freeplay in the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the snowmobile to an authorized POLARIS dealer for service...

Page 75: ...en the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your vehicle is clear 3 Push the yellow reverse button on the left hand control for one second then release The engine will automatically reduce R...

Page 76: ...and begin to rotate forward The light on the instrument panel will shut off 3 Apply the throttle slowly to make sure the transmission is in forward Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 71 for more information about the engine stop switch and throttle safety switch SYSTEM WHAT IT DOES Ignition Switch Interrupts igniti...

Page 77: ...e tow hitch on the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in the towed object WARNING Braking distances increase when towing loads Slow down to maintain control of the snowmobile If the snowmobile becomes inoperable...

Page 78: ...ne with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is available to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owner...

Page 79: ...ervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to ...

Page 80: ... See Page Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 98 I I I Drive Belt Condition 99 I I I I Clutches 98 C C C Belt Tension I I I I Clutch Sheaves 98 I I I I ENGINE COOLING Engine Mounts I I I I Recoil Rope I I I I Cylinder Head Bolts I I I Cylinder Base Nuts I I I Ignition Timing BTDC I I I VES System C C C I Coola...

Page 81: ... I Brake System 58 94 I Brake Fluid 95 I FUEL MANAGEMENT Idle RPM I I I Throttle Lever 72 I I I I I Oil Pump Lever synchronize I I I Throttle Position Sensor I I I Fuel Vent Hoses 85 I I I I I Fuel Filter 85 R Every 2000 mi 3200 km or Every 2 years Oil Filter 88 R Oil Lines 88 I I I Air Box I I I I I ELECTRICAL Auxiliary Shut Off Switch 62 I I I I I Throttle Safety Switch 71 I I I I I Ignition Swi...

Page 82: ...on Fasteners I I I I I Steering Fasteners I I I I C Cooling Fins and Shroud I I I I Drive Shaft Bearing 84 L L L I Skags Wear Bars 109 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 93 I I I I I Hood and Side Panel Fasteners 81 I I I I I Rear Wheel Idler Bolts 105 I I I I I Idler Bolt Jam Nut 105 I I I I I Handlebar Centering I Tether Switch and Strap 62 I I I I I Track Alignment...

Page 83: ...place before starting the engine To open a side panel rotate the two 1 4 turn fasteners at the upper edges of the side panel Release the side panel strap at the lower edge of the panel To remove an open side panel pull the panel outward to release the tabs at the lower edge of the panel Removing the hood is not recommended Any service requiring the removal of the hood should be performed by an aut...

Page 84: ...ned in the Periodic Maintenance Table beginning on page 78 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 ...

Page 85: ...n cloth 5 Reinstall the fill plug Torque to 6 10 ft lbs 8 13 Nm Oil Change 1 Position the vehicle on a level surface 2 Place a drain pan under the drain plug Remove the drain plug Allow the oil to drain completely 3 Clean off all metal shavings from the plug TIP The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 4 Reinstall the drain plug T...

Page 86: ... Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel This should take approximately two pumps Do not use more than four pumps Fitting ...

Page 87: ...ty fuel will shorten the life of the fuel filter and result in poor engine performance Always store fuel in clean fuel containers If low fuel pressure or reduced engine performance occurs between the recommended fuel filter service intervals the filter may need replacement See your dealer Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after p...

Page 88: ...e spark plugs at the intervals outlined in the Periodic Maintenance Table beginning on page 77 Use recommended spark plugs with the proper gap Use only resistor type spark plugs Torque spark plugs to 18 22 ft lbs 24 30 Nm Always carry spare spark plugs NOTICE Using non recommended spark plugs can result in serious engine damage A spark plug with a heat range too high will always cause engine damag...

Page 89: ...4 Reverse the procedure for spark plug installation Torque to specification 5 Reinstall the spark plug cap Spark Plug Condition Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service TIP The tip should not be white A white insulator tip...

Page 90: ...tion every 1000 miles 1600 km as outlined in the maintenance charts beginning on page 77 Oil Filter Please see your dealer for replacement of the in line oil filter every 2000 miles 3200 km as outlined in the maintenance charts beginning on page 77 ...

Page 91: ...50 Premix Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are Coolant bottle overflow tank Pressure cap Connecting hoses Always maintain the coolant level at or slightly above the FULL COLD mark on the ...

Page 92: ...gine frequently to allow it to cool down Flashing Indicator If the indicator flashes continued operation could result in serious engine damage The system will automatically reduce engine power and create a misfire condition Stop the engine immediately Allow the engine to cool down If engine overheating seems to be caused by something other than poor cooling conditions see your dealer for service F...

Page 93: ...t this time 5 Remove the bleed screw from the water outlet manifold and or the thermostat housing Allow the coolant to bleed through the system until it runs out the bleed holes Reinstall the bleed screw into the manifold 6 Add coolant to the coolant bottle to the maximum mark 7 Reinstall the side panel Always ensure that the hood and side panels are securely in place before starting the engine 8 ...

Page 94: ...ecting CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running 1 Open the side panels and remove the hood See page 81 2 Inspect the muffler and pipes for cracks or damage 3 Check for weak or missing retaining springs or damper support grommets 4 Check for loose clamps on the pipe covers ...

Page 95: ... the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 3 Loosen the adjuster bolt jam nut 4 Finger tighten the adjuster bolt until it can no longer be adjusted by hand then back off 1 4 turn 5 Tighten the jam nut while holding the adjuster bolt Torque to 21 ft lbs 28 Nm 6 Reinstall the side panels 7 Release the brake lever lock Jam Nut Adjuster Bolt ...

Page 96: ...brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 inch or 1 5 mm Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thickness is less than 1 16 inch or 1 5 mm 4 Anti rattle springs come...

Page 97: ...ake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury WARNING Keep the master cylinder cover free of dirt and debris The vent slits allow for ...

Page 98: ...2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 inch 6 8 cm below the lip of the reservoir opening Reinstall the gasket and cover 3 Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valv...

Page 99: ...g the headlight assembly 2 Remove the wire harness connector from the back of the headlight 3 Grasp the bulb housing and turn it counter clockwise to remove the bulb 4 Apply dielectric grease to the socket and install the new bulb Rotate the bulb 1 4 turn clockwise to secure it 5 Reinstall the connector to the back of the headlight 6 Secure the foam shield Taillight Brake Light Replacement The tai...

Page 100: ...repairs have been made All clutch maintenance and repairs must be performed by an authorized POLARIS dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty NOTICE The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Clutch Alignment Offset Clutch ali...

Page 101: ...ed edges missing cogs cracks and excessive looseness Replace the belt if any of these conditions exist Always carry a spare drive belt Store the spare belt in the belt clip located under the left side 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 ...

Page 102: ... and apply downward pressure while measuring at point 2 This measurement should be 1 1 4 inches 3 2 cm Drive Belt Adjustment 1 Loosen the 7 16 inch jam nut on the belt width adjuster 2 Using a 1 8 inch Allen wrench turn the set screw inward clockwise to increase the distance between the sheaves or outward counter clockwise to decrease the distance 3 Tighten the jam nut 1 2 ...

Page 103: ...ward motion 2 Turn the ignition key off Wait for the engine to come to a complete stop 3 Lock the parking brake 4 Remove the left side panel 5 Rotate the driven clutch counter clockwise 1 4 turn by hand to ensure forward engagement 6 Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves ope...

Page 104: ...n the open position install the drive belt TIP Install the belt so that the numbers can be read correctly on the left side of the vehicle or in the direction in which the belt was originally installed 2 Wiggle the belt to remove slack while removing the L wrench 3 Reinstall the side panel 4 Break in the new belt See page 66 ...

Page 105: ...l needs snow for lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid ope...

Page 106: ...nsion and alignment TIP Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the snowmobile and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel 4 Measure at the point where the weight is hanging TRACK T...

Page 107: ...e equal adjustment on both sides of the track 9 Repeat the measurement on the other side of the track TIP Check more frequently when the snowmobile is new 10 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 11 Check track alignment see page 106 and adjust as necessary 12 Tighten the locknuts 13 Tighten the idler shaft bolts 14 ...

Page 108: ... Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track runs to the left loosen the idler shaft bolts then loosen the left locknut and tighten the left adjusting bolt If the track runs to the right loosen the idler shaft bolts then loosen the right locknut ...

Page 109: ...107 MAINTENANCE Steering System Steering Inspection Each week or before a long ride check all steering system fasteners and tighten if necessary ...

Page 110: ...our 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 to the service manual or see your dealer for this service 1 Place the handlebars in a straight ahead position 2 With only vehicle weight compressing the suspension measure 10 inches 25 4 cm forward fr...

Page 111: ...cle control while turning 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 fro...

Page 112: ...a wear limit indicator groove to indicate the minimum permissible slide thickness 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 Replace when worn to top of groove Minimum Thickness ...

Page 113: ...onnect the red positive battery cable last 4 Remove the battery Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 113 before installing the battery 1 Ens...

Page 114: ...cted during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully ch...

Page 115: ...y explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Tip Always verify battery condition before and 1 2 hours after the end of charging State of Charge Voltage Action Charge Time Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts ...

Page 116: ...ventive measures to aid against deterioration and to prolong the useful life of many components See page 118 for the part numbers of POLARIS products Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood side panels chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be ...

Page 117: ...od of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the container running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel Do not allow the snowmobile to run out of fue...

Page 118: ...Center Distance 11 5 inches 29 cm Drive Belt P N 3211115 Drive Clutch Type P 85 Driven Clutch Type LW Team Roller Reverse Reverse Transmission Electronic Reverse Engine and Cooling Engine S5118 6044 OS6G Displacement 599 cc Cylinders 2 Bore x Stroke mm 77 25 x 64 Alternator Output 400 watt Throttle Body 1204816 Throttle Body Bore Size 46 mm Idle RPM 1700 200 Rated Operating RPM 8250 0 250 Cooling ...

Page 119: ...iven Helix Chaincase Gearing Pitch Shaded cells indicate factory settings 0 450 0 1500 10 64 1321585 Black Green 7042083 Red Black 7043058 56 42 36 LW ER 5135403 20 42 72 Pitch 450 900 1500 3000 10 62 1321586 900 1500 3000 5000 10 60 1321587 1500 2100 5000 7000 10 58 1321588 2100 2700 7000 9000 10 56 1321684 2700 3350 9000 11000 10 54 1321685 ...

Page 120: ...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 Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2871329 Dielectric Grease Nyogel Coolant 2880514 Antifreeze 50 50 Premix qt 95 l 2880513 Antifreeze 50 50 Premix gal 3 8 l Additives Mi...

Page 121: ...ake sure the fuel valve is on Make sure tank contains fuel Ice may be in the fuel line filter or pump Add isopropyl alcohol to the fuel system SEE YOUR DEALER Poor engine compression This indicates a major engine problem that must be repaired before operating SEE YOUR DEALER Engine lacks power Fouled or defective spark plug s Replace the plug s Fuel filter loss of high RPM power SEE YOUR DEALER Pl...

Page 122: ...rive away from slow speed Drive belt surface flat spots Inspect and replace as needed Noise in drive system Broken drive clutch components SEE YOUR DEALER Bearing failure chaincase jackshaft or front drive shaft SEE YOUR DEALER Drive belt surface flat spots Inspect and replace as needed Drive chain loose or worn sprocket teeth broken Inspect and adjust or replace SEE YOUR DEALER Harsh drive clutch...

Page 123: ...void riding in high ambient temperatures Check for snow ingestion Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the snowmobile in extremely cold weather and warm it up Break snowmobile loose from the snow Poor engine performance Check for fouled plugs and water ice or dirt in the fuel tank or fuel line Loading snowmobiles onto trailers...

Page 124: ...Too little weight transfer when climbing Refer to the suspension adjustment and set up information beginning on page 48 Machine darts from side to side See your 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 Front end pushes Check for worn skags Check for ...

Page 125: ...n this manual Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following information 1 Serial number 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experienced 6 Length of time and conditions of operation 7 Previous correspondence Use the page provided near t...

Page 126: ...ed by POLARIS including but not limited to Two year extended engine coverage Two year powertrain coverage Extended service contract See your dealer for details and separate terms and conditions for any promotional warranties Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this regi...

Page 127: ... components use of aftermarket components unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty excludes damages or ...

Page 128: ... AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EX...

Page 129: ...the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be...

Page 130: ...utside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warra...

Page 131: ...components of systems if their only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This Emissions Limited Warranty does not cover components if their failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the fol...

Page 132: ... or workmanship This Limited Warranty does not cover damage due to accidents abuse or improper handling maintenance or use This Limited Warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This Limited Warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyo...

Page 133: ...er each 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 ...

Page 134: ...132 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 135: ...gnostic Display Mode 45 Disabled Operators 12 Display Standard Metric 38 D Drive Belt Adjustment 100 Belt Safety 18 Break In 66 Condition 99 Installation 102 Removal 101 Drive Belt Deflection 100 Drive Chain Tension 93 Driver Awareness 14 Driveshaft Bearing Lubrication 84 Driving Downhill 17 Driving in Hilly Terrain 17 Driving on Slippery Surfaces 16 Driving Responsibly 19 E Electrical Connections...

Page 136: ...nance Recommendations 9 Maneuverability 18 Metric Standard Display 38 N Noise 6 O Odometer Engine Hour Display 37 Oil Change Chaincase 83 Oil Filter 88 Oil Injection System 66 Oil Level Chaincase 83 Oil Level Injection 70 Oil Lines 88 Oil Recommendations 65 Operating in Deep Snow 16 Operation Warning 24 25 Operator Safety 8 20 Overheating Engine 90 P Parking Brake Lever Lock 59 Passenger Warning 2...

Page 137: ...Handlebar Grip Warmer Switch 27 Headlight Dimmer Switch 27 Ignition Switch 62 Mode Select Buttons 32 Mode Set Switch 32 Tether Switch 62 Throttle Safety Switch 71 Thumbwarmer Switch 27 T Taillight Brakelight Replacement 97 Tether Switch 62 Throttle Block Alignment 53 Throttle Lever 72 Throttle Lever Inspection 57 Throttle Safety Switch 57 71 Tool Kit 28 Torsion Spring Preload 50 Towing 75 Track Al...

Page 138: ...PMS 419 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 9925991 Rev 01 Printed in USA ...

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