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Polaris 600 IQ Touring 2009, Owner'S Manual

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Polaris 600 IQ Touring 2009 Owner'S Manual Download Page 121

118

MAINTENANCE

Drive Chain Tension

Check drive chain tension weekly 

and before each long trip. To 

obtain correct chain tension:
1. Rotate the driven clutch 

counterclockwise to move all 

chain slack to the tensioner 

side. Lock the brake lever 

lock, or have an assistant 

hold the brake lever firmly.

2. Loosen the adjuster bolt jam 

nut.

3. Finger tighten the adjuster 

bolt until it can no longer be 

adjusted by hand, then back off 1/4 turn.

4. Tighten the jam nut while holding the adjuster bolt. Torque to 18-23 

ft. lbs. (24-31 Nm).

5. Release the brake lever lock.

Adjuster 

Bolt

Jam 

Nut

Summary of Contents for 600 IQ Touring 2009

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Page 3: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 4: ...r 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 information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is i...

Page 5: ... the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole o...

Page 6: ... of your snowmobile s controls and features The Perfect Fit 54 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 66 This section explains procedures that must be performed before riding Operation 75 This section explains proper engine break in operation of features and general operating procedures Maintenance 89 This section...

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Page 8: ... are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding clubs When teaching inexperienced operators to ride set up a predetermined course for practice Ma...

Page 9: ...of our environment Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that 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 ...

Page 10: ...aris 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 _____________________________________________________________ lower right side of the tunnel Engine Serial Number on valve cover _______________________________________ Key Number ____________________________...

Page 11: ...with their meanings before reading the manual The safety alert symbol on your vehicle or in this manual indicates the potential for serious injury WARNING A WARNING indicates a potential hazard that may result in serious injury or death CAUTION A CAUTION indicates a potential hazard that may result in minor injury NOTICE A NOTICE indicates a situation that may result in damage to the vehicle ...

Page 12: ... 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 13: ...k its operation WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track ser vice and alignment pr...

Page 14: ... must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cel lular telephone Always carry the owner s manual on your snowmobile For added pro tection purchase an...

Page 15: ... will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be prep...

Page 16: ...ld never be operated with more than two people on board When traveling with a passenger it s the driver s responsibility to operate the snowmobile safely Slow down Control becomes more difficult with two people on board More space is required to make turns and longer distances are necessary for stopping WARNING Control becomes more difficult with two people on board More space is required to make ...

Page 17: ... rear of the machine may reduce your ability to steer Do not exceed carrier and rack weight limits and do not allow a passenger to sit on the seat back or the cargo carrier WARNING Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Do not allow disabled persons to operate this vehicle ...

Page 18: ...wmobile 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 and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your snowmobile to a stop in the distance illu minated by the headlight WARNING High speed driving es...

Page 19: ...o 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 way out Variances in snow depth and or water currents ma...

Page 20: ...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 ava lanche advisory to get current weather and snow stability information Fo...

Page 21: ...your speed to a minimum Apply just enough throttle to keep the clutch engaged allowing the engine s compression to help slow the snowmobile and keep it from rolling freely downhill WARNING Ice and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice WARNING When driving on long downhill stretches pump the...

Page 22: ...revent it from rolling back down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill side of the snowmobile pull the rear of the snowmobile around and point the front end and skis downhill Remount the snowmo bile restart the engine release the parking brake and descend the hill carefully WARNING Never attempt an abrupt change of direction when operating on...

Page 23: ...speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put t...

Page 24: ...snowmobile becomes stuck in snow clear the running board area of snow then step down the snow in front of the snowmobile so that when the throttle is opened the snowmobile will be able to climb up and over the snow WARNING Inadequate cooling and lubrication will lead to overheating of the slide rail and track causing premature wear damage and failure which can result in serious injury Reduce speed...

Page 25: ...l as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide pro tection under normal riding conditions Your snowm...

Page 26: ... 93 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min 5 min Wind Speed in KPH 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...

Page 27: ... replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Clutch Cover Warning This warning decal is found under the hood on the clutch cover WARNING Do not operate with hood open Do not attempt adjustment with engine running Do not operate engine with plenum belt guard removed Never run engine with drive belt removed Never service clutches...

Page 28: ...iles designed for an operator and one passenger have a warning decal on the left console For more information on operating with a passenger see page 13 WARNING This vehicle is designed for operator and ONE passenger only Track Warning WARNING Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death No Passenger Warning or...

Page 29: ...injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Machine stopped and engine at idle push yellow button on LH con trol to reverse Flashing light on dash indicates reverse operation Push button again to return to fo...

Page 30: ... wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age require ments 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 crossi...

Page 31: ...ragging the snowmobile 4 Hood 5 Headlight 6 Windshield 7 Operator Seat 8 Passenger Seat 9 Backrest 10 Passenger Grab Handle 11 Cargo Bag 12 Grab Handle Heater Switch 13 Taillights 14 Rear Bumper 15 Snow Flap 16 Track 17 Suspension 3 4 5 6 2 1 7 8 9 12 13 14 15 16 17 10 11 ...

Page 32: ... 6 Hood Hold Down Straps 7 Handlebar Grip Warmer Switch 8 Thumbwarmer Switch 9 Electronic Reverse Button 10 MFD Control 11 Headlight Dimmer Switch 12 Parking Brake Lock 13 Brake Lever 14 Engine Stop Switch 15 Throttle Control 16 Ignition Switch 16 1 13 14 15 12 7 8 9 10 11 3 1 6 4 5 ...

Page 33: ...ve the backrest for ward for operator use or rear ward for passenger use 3 Always tighten the knobs securely after adjusting Adjustable Headlights Move the adjuster to the left to lower the headlight beam Move the adjuster to the right to raise the headlight beam Radiator Compartment Access Panel The access panel is provided for cleaning debris from the radiator Operator Passenger Raise Lower ...

Page 34: ...ure cargo before operating Do not exceed the weight limit Do not allow a passenger to sit on the seat back or the cargo area 1 Push down on the seat latch lever which is located at the lower rear of the passenger seat 2 Lift up the seat and remove it from the chassis 3 Reverse the procedure to reinstall the seat Press down firmly on both sides of the seat to engage the latch Verify that the latch ...

Page 35: ...ted for rider preference 1 Unscrew and remove the knob assemblies that secure the grab handles 2 Reposition the grab handles to one of the three available posi tions on the grab handle tube between the operator seat and the passenger seat 3 Reinstall the knob assemblies and tighten securely Knob Assembly ...

Page 36: ...cket next to the right hood hold down If you install an accessory outlet on your model always install it in the recoil pocket The fuel filter is installed in the upper console area Do not install an outlet on the upper console WARNING Serious injury could occur if sparks ignite a fuel supply Do not install an accessory 12 volt DC outlet on the upper console Install the outlet in the recoil pocket ...

Page 37: ... adjustability Removing this lockout and using RIDER SELECT posi tion 6 or 7 will result in the handlebars and brake lever contacting other com ponents and interfering with steering and braking This could lead to loss of control resulting in serious injury or death Always be sure that the handle bars and brake lever do not contact any other snowmobile components at any steering position AND at any...

Page 38: ...rail Riding Boondocking Deep Snow Riding Rider weight is centered on the snowmo bile providing balance comfort and con trol for both novice and experienced riders This is the recommended position for most riding situations 6 7 Snowcross Steep Hill Climbing Only Rider weight is ahead of the center of the snowmobile adding weight to the skis and making the snowmobile heavier in the front These posit...

Page 39: ...Do not lubricate the RIDER SELECT mechanism Doing so could cause loss of control and result in serious injury or death The RIDER SELECT mecha nism is lubricated for life at the factory WARNING Some aftermarket accessories including windshields and cargo bags may interfere with the handlebar Such accessories could limit your ability to steer the vehicle and or may contact the brake lever This could...

Page 40: ... cause of a flashing MIL or high temperature indicator serious engine damage may occur with continued operation See your Polaris dealer 1 Verify that all electrical connections are secure 2 Check battery voltage on the gauge and install a new battery if volt age is low see page 52 3 Verify that engine temperature is within the recommended operating range See the Turbo Boost chart on page 38 A flas...

Page 41: ...Reverse is selected speed sensor error Reverse 5300 Engine will mis fire at higher engine speed Defective rollover switch speed sensor error Rollover 6000 Throttle stuck throttle lever depressed speed sensor error Throttle stuck throttle safety switch high 5450 Throttle stuck throttle lever at idle position Throttle stuck throttle safety switch low 2400 Maximum vehicle speed speed sensor error Max...

Page 42: ...r stutter If you do not notice the flashing indicator on the MFD or do not suffi ciently cool the snowmobile the engine will misfire to alert you to look at the MFD and take action Again driving the snowmobile into soft snow or packing snow onto the heat exchangers should cool the engine 3 The engine will stop If the engine reaches an extreme temperature where damage becomes possible the system wi...

Page 43: ...fely If the system senses detonation beyond a preset limit it retards ignition timing and adds fuel to reduce the detonation and prevent engine damage When the detonation returns to a permissible level the system will return spark and fuel to normal allowing the engine to run at rated power levels Fail Safe The knock sensor includes a sensor fail safe system to prevent the engine from damage if th...

Page 44: ...or Item 1 RPM or Speed Altitude if equipped Service Interval 2 Electrical System Voltage Level 3 MAX Maximum MPH KPH or RPM MPH Miles per hour KPH Kilometers per hour RPM Engine crankshaft revolutions per minute 4 Air Temp if equipped Engine Temp Degrees Celsius Degrees Fahrenheit 5 Miles Kilometers 6 Hours Trip 1 Trip 2 Trip F Service Label Altitude Label 7 Fuel Level FS or Turbo Boost Turbo mode...

Page 45: ...ng or with the engine off If the engine is off make sure the stop switch is pressed down and turn the ignition key to the START position briefly to activate the gauge The gauge will illuminate for about 90 seconds Standard vs Metric The MFD will display either standard or metric units of measurement While viewing a screen that displays measurements MPH km h or temperatures press and hold the MODE ...

Page 46: ... display the tachometer option 1 If the analog is set to show the tachometer the digital screen will show the speedometer option 2 To change viewing preferences press and hold the MODE button for three seconds When the button is released the new setting becomes active and screen colors change See table below Option Analog Display Digital Display Analog Screen Digital Screen 1 Speed RPM Blue MPH Bl...

Page 47: ...d See page 43 Press and release the SET button to cycle through the following screens odometer trip 1 odometer trip 2 odometer fuel trip odometer if fuel is low and clock if equipped Use the following procedures to make changes to these screens Odometer Setting The odometer records the vehicle s total distance traveled since manufacture The odometer cannot be reset Trip Settings Trip 1 and Trip 2 ...

Page 48: ...pped with an electronic fuel gauge The fuel symbol and the last fuel bar on the MFD gauge if equipped will blink when the fuel level reaches 1 8 of a tank The Trip F odometer records distance traveled and the fuel symbol continues to blink until enough fuel is added to raise the level above 1 4 of a tank The Trip F odometer will automatically reset to zero after refueling ...

Page 49: ...e seconds 4 When the hour starts flashing press the SET switch once to advance one hour Press and hold the SET button to advance the hours quickly 5 Press and release the MODE button to save the hour The minutes will begin flashing 6 Set the minutes in the same manner 7 When finished press and release the MODE button to save the new setting If the MODE button is not pressed within ten seconds the ...

Page 50: ...llowing screens hour meter engine temperature air temperature available as an acces sory altimeter available as an accessory and turbo boost if equipped Hour Meter The hour meter records the total hours of engine operation since manufacture This meter cannot be reset Engine Temperature A thermometer measures water temperature giving an indication of engine temperature Air Temperature if equipped T...

Page 51: ... quickly by 100 foot 30 m incre ments 5 Adjust the altitude display to within 50 ft 15 m of current altitude Tip The gauge reads barometric pressure and allows the rider to compensate for daily fluctuations in air pressure The gauge can adjust the displayed altitude to 1300 ft 396 m from the preset value It will adjust up to 1300 ft 396 m above the calibrated altitude Once the 1300 ft 396 m offset...

Page 52: ...d Maximum RPM The gauge automatically logs the maximum speed and engine RPM even if the history program is not active in the display 1 Enter the History Program 2 Press and release the SET button until one of the two screens is active Tip The MPH and RPM values are both reset at the same time Reset the values before each run to obtain accurate readings 3 Press and hold the SET button for three sec...

Page 53: ...odometer area and ENG will flash in the icon area for five seconds each time the engine is started until the service reminder is reset Use the following procedures to reset the reminder To reset the reminder at the existing interval 1 Enter the History Program 2 Press and release the SET button until the service interval screen is active 3 Press and hold the SET button for ten seconds continuing t...

Page 54: ...active 3 Press and hold the SET button for five seconds until the hours begin to flash Immediately release the button 4 Press the button again up to five times to advance the reminder in 50 hour increments Tip The maximum interval is 250 hours 5 Press and release the MODE button to save the new settings To disable the service interval reminder 1 Press the SET button once after reaching 250 hours o...

Page 55: ...ry compart ment It has a red wire and a brown wire with a white stripe It s located about three inches down the main harness from the point where the harness connects to the MFD 3 Cut the plastic cable tie from the outside of the compartment 4 Carefully cut the bottom of the compartment opposite the wires to separate the heat sealed seams Squeeze the corners of the compart ment inward so the batte...

Page 56: ...Make sure the taped seam of the compartment faces the downward side of the wire harness 9 Install a cable tie to secure the compartment to the wire harness in the same location where the previous cable tie was located Make sure the battery wires are not stretched tight Gauge Cleaning 1 Wipe the gauge face as needed using a clean cloth and a mild soap and water solution Wipe dry with clean soft clo...

Page 57: ... starting with factory settings and then customizing each adjustment individually to suit rider preference The snowmobile should be methodically tested one change at a time under the same conditions trail and snow condi tions vehicle speed riding position etc after each adjustment until the best ride is achieved IFS Components 1 Skis 2 Front shocks and springs 3 Rod ends 4 A arms IFS Adjustment Op...

Page 58: ... most riders and conditions Please see your Polaris dealer for assistance before attempt ing to adjust preload Increasing the spring preload too much may adversely affect the han dling of the snowmobile and the performance of the rear suspension Decreasing the spring preload too much may allow the lower spring retainer to fall off ...

Page 59: ...gen pressure The upper chamber adjusts the main spring rate The lower chamber adjusts preload See your Polaris dealer for more information WARNING Changing shock valving requires special tools and a sound knowledge of mechanical theory tool use and shop procedures to perform the work safely and correctly Shocks contain high pressure nitrogen gas Use extreme cau tion when handling high pressure ser...

Page 60: ...ee your dealer Suspension Performance Tips Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride In deep snow a new rail slide will offer improved performance ...

Page 61: ...seated measure the distance between the ground and the rear bumper at the exact location used for measure ment X This is measurement Y To determine sag commonly referred to as ride in subtract measure ment Y from X sag X Y If the measured sag is incorrect adjust the FRA position and or rear torsion spring preload Tip This is only an initial setup and final spring preload may vary based on rider pr...

Page 62: ...tly more effort Different rate torsion springs are available if a firmer ride is desired See your dealer for more information Suspension Coupling On all Polaris snowmobile rear suspensions there are two torque arms that control the movement of the rail beam Prior to the advent of sus pension coupling these torque arms could move independently of each other Rear suspension coupling links the moveme...

Page 63: ...ate for all riders and conditions Rear To Front Coupling and the Rear Rear Scissor Stop RRSS The rear rear scissor stop RRSS couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen dent movement between the rear torque and the front torque arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight ...

Page 64: ...est for most trail riding conditions To decrease weight transfer under acceleration for improved corner ing rotate the RRSS to a higher position To increase weight transfer or ski lift during acceleration rotate the RRSS to a lower position Tip Your dealer can help you with initial setup and additional setup instruc tions to help you achieve your opti mum ride A scissor stop tool is also available...

Page 65: ... the adjuster block turn han dlebar to left or right for access to back nuts Tip If necessary pry the blocks apart with a screwdriver 3 Adjust the handlebar to the desired height Be sure han dlebars 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 4 Torque the front bolts first then torque...

Page 66: ...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 following areas brakes clutches fuel systems and exhaust systems Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service ...

Page 67: ...lack of clearance between upper carrier wheels and track Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tunnel Track studding will enhance braking control on hard packed snow or ice but extreme caution is still required on such surfaces Steering abil ity may be reduced on hard packed snow or ice When stu...

Page 68: ...ntain a proper balance between the number of studs and the length of carbide on the skags the more studs you use the longer the carbide on the skags should be See your dealer s track studding chart Wear Strips To avoid excessive tunnel wear tunnel wear strips must be installed whenever track studding is used Install the appropriate wear strip kit See your dealer Wear strips are designed for a spec...

Page 69: ...Lock Brake Lever Brake System 69 70 119 Throttle Lever 67 Throttle Safety Switch 67 Auxiliary Shut Off Switch Engine Stop Switch 73 87 Ignition Switch 73 87 Taillight Brakelight Headlight 73 Coolant Level 113 Gearcase Oil Level 105 Engine Oil Level 94 Foam Oil Breather Element 102 Suspension Mounting Bolts 72 Skags Wear Bars 65 135 Ski Saddle and Spindle Bolts 72 Hood Straps Latches 68 Seat Latche...

Page 70: ...he 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 func tion smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately n Throttle Safety Switch Test the throttle safety switch system before the snowmobi...

Page 71: ...place before operating the snowmo bile n Steering System Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage If your snowmobile is equipped with RIDER SELECT perform this check in both the full up and full down ...

Page 72: ...ulic system Refer to the brake bleeding infor mation on page 121 Brake Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 120 Check for the presence of air in the fluid system See page 121 for more information or see your dealer for service WARNING Continued use of spongy brakes may cause a complete loss of brakes which c...

Page 73: ... 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 t...

Page 74: ...e loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle Use of traction products such as studs increases the possibility of track dam age and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubricatio...

Page 75: ...the follow ing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 131 Rear idler adjusting bolt locknuts Tightness Torque arm bolts Tightness Carrier and bogie wheel bolts Tightness Front torque arm limiter strap Condition Rail slide Condition 132 Track Tension 130 All rear suspension components Lubrication 104 Ski r...

Page 76: ...sure the engine stops when the ignition switch is turned to OFF n Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating n Mirror Adjustment If equipped adjust your mirrors so they can be used to their full advan tage n Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe dis...

Page 77: ...evel before operating a snowmobile that has tipped over or rolled over In the event of a tip over or rollover the engine will stop To restart the engine turn the key to the OFF position then restart WARNING Operating a snowmobile with accident damage can result in serious injury or death Do not operate the snowmobile if vehicle components have been damaged in a collision or tip over Have the snowm...

Page 78: ...es or sparks 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 WARNING The engine exhaust from this product cont...

Page 79: ...ll throttle or high speeds for extended periods during the break in period Use of non recommended oil may cause serious engine damage Always use the recommended oil for your Polaris snowmobile 1 Fill the fuel tank with the recommended fuel See page 81 2 Check the oil level in the oil tank See page 94 Add oil if necessary to maintain at the recommended level 3 Drive slowly at first Vary the throttl...

Page 80: ...s attempt to start the engine without using the throt tle If two to three attempts are unsuccessful apply 1 8 to 1 4 throttle while cranking the engine Ease off the throttle immediately when the engine starts Continue to apply just enough throttle to keep the engine running until it idles smoothly 4 Turn the key to START to crank the engine Release the key to the ON position when the engine starts...

Page 81: ...wmobile battery Never attempt to jump start a discharged battery that is frozen WARNING Improperly connecting or disconnecting jumper cables can result in an explo sion and cause serious injury or death When connecting jumper cables always connect the negative usually black cable last When removing jumper cables always disconnect the negative usually black cable first WARNING Loose fitting clothin...

Page 82: ...cable to the fuel system or fuel lines 8 Pull back the red plastic boot covering the positive terminal of the weak battery Connect one end of the positive jumper cable to the positive terminal of the weak battery 9 Connect the other end of the positive jumper cable to the positive terminal of the charged battery NOTICE Make sure that the end of the negative cable by the weak battery is not contact...

Page 83: ...sure that they have a good electrical connections Repeat step 14 16 If the engine still does not start remove the jumper cables as out lined in step 17 and transport the snowmobile to an authorized Polaris dealer for service 17 Carefully remove the jumper cables in this order A Remove the negative end of the jumper cable from the snowmobile chassis B Remove the negative end of the jumper cable fro...

Page 84: ...nt Always protect painted surfaces when handling fuel Fuel Level The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1 8th tank There will be approximately one gallon of fuel remaining Refuel as soon as possible Do not allow the snowmo bile to run out of fuel Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl...

Page 85: ...nd it while warming up the track Do not use excessive throt tle during warm up or when the track is free hanging Be sure the rear sup port is stable WARNING Use of traction products such as studs ice growsers etc will increase the possibility of track damage and or failure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the sno...

Page 86: ...ff 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 revo lutions Tip It will take longer to warm up the track sufficiently during colder outdoor temperatures 4 Release the throttle apply the brakes shut off the engine and lower the snowmobile to the ground 5 Grasp the skis by their front loops and move ...

Page 87: ...ause vehi cle speed and engine speed to be limited This four stroke snowmobile has a self diagnostic check of the throttle safety switch The switch operation is checked through the engine con trol unit for correct operation If a defective switch is detected by the self diagnostics system the MIL will illuminate Take your snowmobile to an authorized Polaris dealer for diagnosis and repair if the MI...

Page 88: ...oesn t start take the snowmobile to an authorized Polaris dealer for service Tip Excessive freeplay in the throttle cable may cause the safety switch to acti vate preventing the engine from starting If this occurs return the snowmo bile to an authorized Polaris dealer for service Turbo Noise Turbo models Under some conditions when the throttle lever is released the boost pressure dump valve will r...

Page 89: ...se but ton on the left hand control for one second then release Tip A reverse light on the instrument panel will indicate that the transmission is in reverse 4 Apply the throttle slowly to make sure the transmission is in reverse Tip If the engine stops running the transmission will be in forward gear when it s restarted WARNING Improper reverse operation even at low speeds may cause loss of contr...

Page 90: ... off 3 Apply the throttle slowly to make sure the transmission is in for ward n Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 84 for more information about the engine stop switch SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Engine Stop Switch Interrupts ignit...

Page 91: ...move the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary NOTICE Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing WARNING Objects towed with a rope have no braking power and can easily colli...

Page 92: ... 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 Specifications and adjustments for engine tune ups ar...

Page 93: ...rs become the responsibility of the regis tered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to service or make adjust ments to your snowmobile If you re not familiar with safe service or adjustment p...

Page 94: ...ver feel O Coolant 113 Inspect level add as needed O Brake fluid 120 O CHANGE EVERY 2 YEARS Hood Latches 68 Secure properly replace if damaged O Seat Latches 67 O Rail Slide 132 Inspect for wear or damage replace when worn O Foam Oil Breather Element 102 Check pre ride clean or replace with each oil change Clean after tipping 3 times onto left side O O O O Front and Rear Sus pension and Steering F...

Page 95: ...Verify alignment adjust as needed O O O Drive Chain 118 Verify tension adjust as needed EVERY Gearcase Oil 105 Check at 500 mi 800 km change every 1000 mi 1600 km O EVERY 1000 1600 Rear Suspension 104 Lubricate pivot shafts more often in wet snow condi tions O O Bearings 103 139 Lubricate drive shaft and jackshaft bearings O O Throttle Cable 103 Lubricate O O Clutches 124 Verify offset alignment i...

Page 96: ...proper routing replace as needed O O Brake Pads Disc 119 Inspect replace if worn or damaged O O Fuel Vent Lines 109 Inspect replace if worn or damaged O O Ski Toe 134 Verify alignment see your dealer for adjustments O O Cooling Fins Shroud Inspect and clean O O Valve Lash See your dealer FS Specifications Intake 0 08 0 15 mm Exhaust 0 15 0 20 mm FST Specifications Intake 0 08 0 15 mm Exhaust 0 18 ...

Page 97: ... s recommendations for ambient tempera ture operation NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands n Oil Level Check Read the entire oil check procedure before checking the oil level The oil level will rise as engine temperature increases The oil level will be lower when the engine is cold To o...

Page 98: ...perature is within the specified range for performing the oil check Allow the engine to cool if necessary When the coolant is within the specified range restart the engine and allow it to idle for no more than 20 seconds to circulate the oil back into the tank 4 Turn the engine off Tip Check the oil level within three minutes before the coolant tem perature and oil level begin to drop 5 Remove the...

Page 99: ...e bottom of the safe operating range on the dipstick 9 If the level is high remove 2 ounces 60 ml and recheck the level NOTICE Do not overfill the oil tank Engine damage may occur Always add oil in small increments and recheck the level to avoid overfilling 10 Recheck the oil level if oil was added or removed making sure the coolant temperature is within the specified range If necessary con tinue ...

Page 100: ...level check procedure begin ning on page 94 4 If oil is not present add 1 2 quart 47 l of the recommended oil Reinstall the dipstick start the engine for no more than 5 seconds stop the engine and recheck for the presence of oil 5 If oil is present continue with the oil level check procedure begin ning on page 94 6 If oil is not present add another 1 2 quart 47 l of oil Reinstall the dipstick star...

Page 101: ...o turn over the engine without starting it You may also need an assistant to help with the oil change 1 Position the vehicle on a level surface 2 Make sure the engine coolant temperature is between 145 and 160 degrees F 63 71 degrees C If necessary start the engine and allow it to idle until the coolant temperature is within the specified range 3 Turn the engine off 4 Open the hood and remove the ...

Page 102: ...from the fuse block 11 Reinstall the left side panel 12 Have an assistant use the ignition key to turn over the engine Crank the engine for 15 seconds 13 Wait 30 seconds to allow the starter motor to cool down 14 Repeat steps 12 and 13 four more times for a total of five cycles 15 Reconnect the oil return line to the oil tank Make sure the hose and clamp are properly seated Make sure the clamp is ...

Page 103: ... Reinstall the 20A EFI Fuse 21 Remove the dipstick from the oil tank Add 2 quarts 1 9 liters of the recommended oil Reinstall the dipstick 22 Start the engine and allow it to idle for 3 5 minutes Make sure the engine coolant temperature is between 145 and 160 degrees F 63 71 degrees C 23 Stop the engine 24 Remove the dipstick from the oil tank Clean the dipstick with a clean shop towel and reinsta...

Page 104: ...d overfilling If the filling and checking procedure is not completed within three minutes rein stall the dipstick Restart the engine and allow it to idle for no more than 20 seconds to circulate the oil back into the tank Continue adding and check ing the oil until the level is slightly above the lower mark in the safe operat ing range on the dipstick Do not overfill 27 Reinstall the dipstick MODE...

Page 105: ...lace the element as recommended The foam oil breather element is located inside the airbox 1 Open the hood 2 Release the airbox cover retaining clips and remove the cover 3 Remove the foam breather element 4 Wash the foam element in soapy water then rinse thoroughly and let dry Tip If soap and water are not readily avail able remove as much liquid as possible by pressing the foam element in paper ...

Page 106: ...the inside of the tunnel This should take approximately two pumps Do not use more than four pumps Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as shown Front Suspension The front suspension and steering components do not require lubrica tion Fitting ...

Page 107: ... Periodic Maintenance Table beginning on page 91 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 sus pension For more information about suspension lubrication and adjust ments see your Polaris dealer IQ Comfort Rear Suspension ...

Page 108: ...numbers of Polaris products The dipstick is located on the lower front side of the gearcase Maintain the oil level in the safe operating range between the upper and lower marks on the dipstick 1 Position the vehicle on a level surface 2 Remove the dipstick and wipe it dry with a clean cloth Reinstall the dipstick 3 Remove the dipstick and view the oil level 4 Add the recommended oil as needed Do n...

Page 109: ...l breather element See page 102 1 Position the vehicle on a level sur face 2 Remove the drain plug and drain the oil into a drain pan Allow the oil to drain completely Tip The sealing surfaces on the drain plug and the gearcase should be clean and free of burrs nicks or scratches 3 Reinstall the drain plug Torque to 6 10 ft lbs 8 13 Nm 4 Remove the dipstick 5 Add 9 oz 266 ml of the recommended oil...

Page 110: ...the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile Use recommended spark plugs with the proper gap Use only resistor type spark plugs Torque spark plugs to 18 20 ft lbs 24 27 Nm Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds If a plug ...

Page 111: ...e engine and the service Tip The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjust ments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are exce...

Page 112: ...olaris dealer Do not attempt to service the fuel pump Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 91 Fuel Lines Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal dete rioration from weather and fuel compounds m...

Page 113: ...or more as shown tighten the belt or install a new belt Air Filter Turbo Inspect the air filter for oil and dirt accumulation at the intervals out lined in the Periodic Maintenance Table beginning on page 91 1 Open the airbox 2 Remove the air filter 3 Shake or pat the filter to clean it or install a new filter Do not attempt to clean the filter with liquids Foam Oil Breather Filter Clean or replac...

Page 114: ...or cracks or damage Check for weak or missing retaining springs or damper support grommets 4 Replace any damaged or missing components 5 Clean the plastic surfaces next to the muffler with aerosol Carbure tor and Throttle Body Cleaner Tip See page 141 for the part numbers of Polaris products 6 Close the hood CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust syste...

Page 115: ...ter Never exceed a 60 antifreeze 40 water mixture See page 141 for the part numbers of Polaris prod ucts Tip Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system 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...

Page 116: ...oir bottle Filler neck Pressure cap Coolant overflow tank Connecting hoses Always maintain the coolant level at the COLD FILL mark on the cool ant overflow tank when the engine is cold NOTICE Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recommended COLD FILL Mark ...

Page 117: ...erature indicator light is illuminated can result in serious engine damage Always stop the snowmobile and cool the engine when the high temperature indicator light illuminates Drive in adequate snow to prevent overheating If you must drive your snowmobile after the high temperature indicator light has illuminated drive in deep snow Drive slowly and stop frequently to allow the engine to cool down ...

Page 118: ... service Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main tenance Table beginning on page 91 In addition bleed the cooling sys tem any time one or more of the following conditions exist A component of the cooling system has been serviced or replaced including coolers radiator engine coolant lines and oil cooler A cooling system failure occurs resu...

Page 119: ...ervoir bottle should be full but may have a small air bubble in the top CAUTION Never start the engine when the pressure cap is removed 6 Reinstall the pressure cap Start the engine and allow it to idle 7 With the engine idling observe the coolant level in the reservoir bottle Make sure that the coolant level is always visible in the bot tle If the level reaches the bottom of the bottle stop the e...

Page 120: ...e cap and add coolant through the filler neck until the reservoir bottle is full Reinstall the pressure cap and start the engine 12 Repeat steps 10 11 until the the coolant level in the bottle no longer falls at an engine temperature of 185 F 85 C or greater 13 Feel the coolers at the rear of the snowmobile rear cooler de icers grippers as equipped These components should be warm to the touch indi...

Page 121: ... chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut 3 Finger tighten the adjuster bolt until it can no longer be adjusted by hand then back off 1 4 turn 4 Tighten the jam nut while holding the adjuster bolt Torque to 18 23 ft lbs 24 31 Nm 5 Release the brake lever lock Adjuster Bolt Jam Nut ...

Page 122: ... is less than 1 16 1 5 mm Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops bring the snowmobile to an authorized Polaris dealer for inspection and adjustment 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 ...

Page 123: ...be black If the sight glass is any color other than black add brake fluid 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 rap idly absorbs moisture from the air The moisture causes the boiling tempera ture of the brake fluid to drop which can lead to early brake fade and the possibility of acc...

Page 124: ...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 brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles 7 After bleeding is complete refill the reservoir to the proper level See page 120...

Page 125: ...lb withdraw the bulb from the housing 5 Grasp the bulb by its metal base and carefully separate the bulb from the harness Installing Halogen Bulbs 1 Hold the bulb by its metal base and install it into the wire harness 2 Insert the bulb into the housing 3 Connect the spring to the housing 4 Carefully flip the spring back into the housing placing it around the wire harness 5 Reinstall the plenum cov...

Page 126: ...s EFI RELAY EX SENSOR GAUGE 20A REVERSE SHIFT Exhaust sensor Gauge Reverse shift Accessory projector beam relay Diagnostic plug IGNITION 20A Ignition relay power EFI 20A Cam phase sensor ECU hold on power Reverse limit switch Forward limit switch Start relay coil Chassis relay coil Ignition relay coil Fuel pump relay coil Fan relay coil Fuel pump relay power PTO injector MAG injector Wastegate IGN...

Page 127: ...ptimum perfor mance Please see your Polaris dealer if you experience a decrease in performance Clutch Center Distance See your Owner s Manual Supplement for recommended center distance for your machine If adjustment is necessary see your dealer 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...

Page 128: ...oom temperature Reinstall it before starting the snowmobile n 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 A This measurement should be 1 1 4 3 2 cm Drive Belt Adjustment TEAM Clutch 1 Loosen the 7 16 jam nut on the belt width adjuster 2 Using a 1 8 ...

Page 129: ...ion Tip For easier accessibility make sure the clutch tool access hole is visible between the 11 00 and 2 00 positions of the clutch sheave 2 Turn the ignition key off Wait for the engine to come to a complete stop 3 Lock the parking brake 4 Open the hood 5 Remove the left side panel 6 Install an L wrench into the open threaded access hole in the outer sheave of the clutch 7 Turn the wrench clockw...

Page 130: ...y operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt removal procedures 2 Rotate the L wrench counter clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the wrench 4 Reinstall the side panel 5 Close and secure the hood ...

Page 131: ...commended for your model Track Inspection 1 Using a hoist safely lift and sup port 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 length of each rod Bend the track to check for break age 4 Replace the track if any rod dam age is found WARNING Broken track rods can cause a rotating track to come off the machine...

Page 132: ...e track warranty NOTICE High speed use on hard packed surfaces is not recommended for models equipped with a deep lug track Track lug damage may occur Keep high speed use to a minimum including frequent slow speed intervals for track cooling WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braki...

Page 133: ...he track at the specified distance see chart ahead of the center of the rear idler wheel Tip Measure at the point where the weight is hanging WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine run ning TRACK TENSION DATA CHART Su...

Page 134: ... to provide equal adjustment on both sides of the track 8 Repeat the measurement on the other side of the track Tip Check more frequently when the snowmobile is new 9 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 10 Check track alignment see page 132 and adjust as necessary 11 Tighten the lock nuts 12 Tighten the idler shaft...

Page 135: ...are evenly spaced on each side If the track runs to the left loosen left locknut and tighten the left adjusting bolt If the track runs to the right loosen right locknut and tighten the right adjusting bolt 4 After adjustments are complete tighten locknuts and torque idler shaft bolts to 35 ft lbs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment n Rail Slide Wear For ease of inspection all...

Page 136: ...133 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners ...

Page 137: ...the skis at point X should be 1 8 to 1 4 3 6 mm greater than the measurement at point Y Tip If the skis are misaligned we recommend that your dealer correct the align ment since camber adjustment may also be affected WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski align ment or camber adjustment S...

Page 138: ...snowmobile so the skis are approximately 6 15 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse the steps to install a skag WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommen...

Page 139: ...hinder vehicle per formance Follow the battery charging instructions on page 138 before installing the battery 1 Ensure that the battery is fully charged 2 Set the battery in the battery holder 3 Connect and tighten the red positive cable first 4 Connect and tighten the black negative cable last 5 Attach the hold down strap 6 Verify that cables are properly routed 7 Reinstall the left side panel W...

Page 140: ...ted 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 cha...

Page 141: ...on before and 1 2 hours after the end of charg ing WARNING An overheated battery may 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 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 142: ... paint The snowmobile should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components Battery Maintenance Remove the battery and recharge it as outlined on page 138 Store the battery in a cool dry place Controls and Linkage Lubricate all bushings and cables at the intervals outli...

Page 143: ...cured away from sharp edges steering linkage moving parts and hot exhaust parts Track and Suspension Moderate track tension should be maintained during summer storage The snowmobile should be supported off the ground to allow the track to hang freely See illustration Transporting the Snowmobile Whenever the snowmobile is transported 1 Be sure the fuel cap and oil cap are installed correctly 2 Alwa...

Page 144: ...Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogel Coolant 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz ...

Page 145: ...may be iced up or fro zen to the ground Jammed or broken chaincase sprocket or chain See your dealer Mechanical failure See your dealer Probable Cause Solution Low battery voltage Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine stop switch is off Lift the stop switch to the ON position ...

Page 146: ... Clogged fuel filter Replace the filter Low battery voltage Recharge the battery to 12 8 VDC Poor engine compression See your dealer Mechanical failure See your dealer Probable Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Mec...

Page 147: ...ug Inspect clean and or replace spark plug Kinked or plugged fuel vent line Inspect and replace Clogged air filter Inspect and clean or replace Air flow through intake is too warm Turbo models Boost is limited until cooler air flows through the intake Engine management system failure See your dealer Engine overheating Stop and cool the engine See the Engine Overheating troubleshooting section on p...

Page 148: ...ator Stop and cool the engine Clean snow and debris from the radiator Probable Cause Solution Worn drive belt Replace with the recommended belt Excessive belt sheave clearance See your dealer Probable Cause Solution Incorrect belt Replace with the recommended belt Incorrect clutch alignment See your dealer Broken or loose engine mount See your dealer Probable Cause Solution Broken drive clutch com...

Page 149: ...rts from side to side Check ski alignment see page 134 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Set static sag see page 58 Check rail slide replace if worn see page 132 Install Accu Trak dual skags see your dealer Front end pushes Check for worn skags Check for binding front suspension...

Page 150: ... Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine perfor mance Check for fouled plugs or water ice or dirt in the gas tank or fuel line Loading machines onto trailers Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the machine com ...

Page 151: ... contained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following information 1 Serial number 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experienced 6 Length of time and conditions of operation 7 Previous correspondence Use the page pro...

Page 152: ...e owner reports theft A In addition to notifying the proper law enforcement officials the owner must call Polaris Customer Service B Owners must provide their name address telephone number and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notifyi...

Page 153: ...s not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for pur poses other than for which it was manufactured The warranty does not cover any dam ages that occur during t...

Page 154: ...st present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at Polari...

Page 155: ...overage in the event of a warranty claim This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamina...

Page 156: ...Coverage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes Damage due to accident fire explosion theft or other causes beyond Polaris control Damage caused by the failure o...

Page 157: ...take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of t...

Page 158: ...at are covered by this warranty This includes all com ponents whose failure increases the snowmobile engine s emissions Replacing or repairing other components not covered by this warranty is the responsibility of the snowmobile owner The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or p...

Page 159: ...dentified in the owner s manual Polaris can deny an emissions warranty claim if any specified critical emissions related maintenance is not performed Performance of other scheduled main tenance is strongly recommended but is not necessary to keep the emissions related warranty valid Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your ...

Page 160: ...er each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 1500 mi 2400 km ...

Page 161: ...158 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 162: ...159 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 163: ...12 117 Cooling System Bleeding 115 117 Cooling System Flushing 115 D DC Outlet 12 Volt 33 Digital Display 41 Disabled Operators 14 Drive Belt 20 Drive Belt Adjustment 125 Drive Belt Condition 125 Drive Belt Deflection 125 Drive Belt Installation 127 Drive Belt Removal 126 Drive Chain Tension 118 Driver Awareness 16 Driveshaft Bearing Lubrication 103 Driving Downhill 18 Driving in Hilly Terrain 19 ...

Page 164: ...nents 41 MFD Digital Display Programs 44 51 MFD Settings 42 43 N Noise 6 O Oil Engine 94 101 Gearcase 105 106 Oil Breather Element 102 Oil Breather Filter 110 Oil Change 98 101 Oil in System Check 97 Oil Level Check 94 96 Operating in Deep Snow 21 Operation Warning 27 P Parking Brake Lever Lock 70 Passenger Warning 25 Polaris Products 141 Pre Ride Checklist 66 74 Pressure Cap Warning 24 R Rail Sli...

Page 165: ...es Stop Switch 84 Throttle Safety Switch 84 T Throttle Cable Lubrication 103 Throttle Lever 67 85 Throttle Safety Switch 67 84 Tip Over Inspections 74 Torsion Spring Preload IQ 59 Towing 88 Track Alignment 132 Track Inspection 71 128 Track Lubrication 129 Track Replacement 128 Track Tension 130 131 Track Warm Up 82 83 Track Warning 25 Traction Products 64 65 Transporting the Snowmobile 140 Trouble...

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