Polaris 600 SWITCHBACK Owner'S Manual Download Page 109

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107

MAINTENANCE

Track Maintenance

Track Tension

5. Check for specified slack between the wear surface of the track clip

and the plastic slider. Refer to the Track Tension Data Chart on page
106.

If the track needs adjustment:

6. Loosen the rear idler shaft bolt.

7. Loosen the locknuts.

8. Tighten or loosen the track adjusting screws to provide equal adjust-

ment on both sides of the track.

9. Repeat the measurement on the other side of the track.

TIP:

Check more frequently when the snowmobile is new.

10. Remove the weight. 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 108) and adjust as necessary.

12. Tighten the locknuts.

13. Tighten idler shaft bolts to 35 ft. lbs. (47.5 Nm).

Slack Measurement

Lock Nut

Track Adjusting

Screw

Track

10 lbs. (4.54 kg)

Idler

Shaft

Bolt

16 inches

(40 cm)

Summary of Contents for 600 SWITCHBACK

Page 1: ...ed warranty coverage Please read the warranty section of this manual carefully IMPORTANT NOTICE TO OWNER Snowmobile Owner s Manual for Maintenance and Safety 600 Switchback 600 Switchback Pro R 600 Switchback Adventure 800 Switchback 800 Switchback Pro R 800 Switchback Pro R Adventure ...

Page 2: ...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 3: ...nal vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever pro duced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information abo...

Page 4: ...minor discrep ancies could result between the actual vehicle and the information presented in this pub lication 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 instr...

Page 5: ...nd features The Perfect Fit 46 This section includes a Suspension Quick Set Up Guide and explains how to make additional suspension adjustments for the perfect riding experience Pre Ride Inspections 60 This section explains procedures that must be performed before riding Operation 67 This section explains proper engine break in operation of features and general operating procedures Maintenance 80 ...

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 Ma...

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

Page 9: ...g a POLARIS key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number ___________________________________________________ Tunnel VIN right side of tunnel ____________________________________________ Engine Serial Number on recoil housing _____________________________________ Key Number _______________________________________________...

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

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

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

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

Page 14: ...If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cel lular telephone Always carry the owner s manual on y...

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

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

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

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

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

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

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

Page 22: ...93 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min 5 min Wind Speed in Km h Actual Thermometer Reading C 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 Equivalent Temperature C Calm 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 3 0 4 7 11 14 18 22 2...

Page 23: ...rchase a replacement Replacement safety labels are pro vided by POLARIS at no charge The part number is printed on the label Clutch Warning This warning label is found on the oil bottle WARNING Do not operate engine with hood or side panels open Do not attempt adjustment with engine running Do not operate engine with the clutch guard removed Never run engine with drive belt removed Never service c...

Page 24: ... 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 reverse Machine stopped and engine at idle push yellow button on LH control to reverse Flashing light on ...

Page 25: ...lothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control the vehicle When operating on hard packed snow ice or when crossing roads steering and braking ability are greatly reduc...

Page 26: ...0 9 1 Nosepan 2 Skis 3 Front Bumper 4 Hood 5 Headlight 6 Windshield accessory 7 Handlebar 8 Operator Seat 9 Taillight 10 Rear Bumper 11 Snow Flap 12 Suspension 13 Track 14 Side Panel 15 Side Panel Fasteners 16 Tool Kit Storage Bag 15 14 16 ...

Page 27: ...on Switch 4 Engine Stop Switch 5 Throttle Control 6 Recoil Starter Handle 7 Parking Brake Lock 8 Handlebar Grip Warmer Switch 9 Thumbwarmer Switch 10 Electronic Reverse Button 11 Mode Set Switch 12 Headlight Dimmer Switch 3 4 5 6 2 1 11 10 12 7 8 9 ...

Page 28: ...26 FEATURES Adjustable Headlights Move the headlight adjuster to the left to adjust the headlight beam upward Move the adjuster to the right to adjust the beam downward Up Down ...

Page 29: ...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 dis played in the lower section of the gauge 4 Press and hold the SELECT button or SE...

Page 30: ...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 31: ...bile will not move when throttle is applied If you wish to use this system see page 37 of the Instrument Cluster section for security system activation and operating instructions Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol non ethanol fuel type setting Verify correct fuel type setting on gauge Low fuel no fuel in tank Refuel with recommende...

Page 32: ...SET switch on the left handlebar NOTICE Certain products will damage the lens and other plastic sur faces 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 33: ...e 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 recom mended oil before further operation See page 73 High Beam Indicator The high beam indicator illuminates when the lights are set to high ...

Page 34: ...ttable trip meters 2 total engine hours of operation fuel level engine tempera ture and diagnostic display mode Setting changes must be made with the engine running or with the vehi cle 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 36 2 3 6 4 5 1 ...

Page 35: ... 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 35 5 Battery Power This ind...

Page 36: ...splays first make sure the information dis play 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 37: ...d 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 second...

Page 38: ...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 39: ...eature activated you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended A locked system will limit engine speed to 3000 RPM which prevents clutch engagement and the snow mobile will not move when throttle is applied If you wish to use this feature you must complete all four tasks on the following pages to have your system activated and to change the secu rity ...

Page 40: ...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 41: ...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 42: ...git 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 dis play screen SECURE ON displays if the system locks Engine speed is now limited and the snowmobile cannot be driven ...

Page 43: ...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 44: ...ystem 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 Acce...

Page 45: ...ive 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 fol lowing 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 46: ...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 47: ...tonation 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 Voltage Too Low 4 Throttle Release Signal Voltage Too High 520194 3 Voltage Too Low 4 Throttle Stuck 7 Chassis Relay Dri...

Page 48: ...r factory and initial suspension charts for the standard spring as well as for accessory springs that are available for heavier or lighter riders Step 1 Set up rear shock spring preload for rider weight Before riding for the first time use the gauge supplied with your snow mobile to adjust rear spring preload to the appropriate setting for actual rider weight Position the narrow end of the gauge f...

Page 49: ...click below full stiff full clock wise or shock damage will occur Test ride the snowmobile and continue making spring and clicker adjustments until you achieve the perfect ride TIP Initially heavier riders may want to set the shock clickers 2 4 clicks higher than lighter riders Ride Experience Adjustment Too much weight transfer Ski pressure is too light Skis push Turn rear shock spring retainer c...

Page 50: ... 46 Spring Guide Stock Spring Accessory 120 Spring Accessory 260 Spring See your POLARIS dealer to order an accessory spring and the gauge calibrated for that spring Rider Weight Dimension Rider Weight Dimension Rider Weight Dimension lbs kg in cm lbs kg in cm lbs kg in cm 120 54 1 5 Min 3 81 90 41 2 375 6 03 240 109 2 125 5 40 130 59 95 43 2 5 6 35 255 116 2 25 5 72 140 64 1 75 4 44 100 45 2 625 ...

Page 51: ...d From body end to spring FOX shocks 3 75 inches 9 52 cm PRO R shocks 3 00 inches 7 62 cm Front Track Shock Clicker 2 clicks clockwise from full soft Front Track Shock Spring Preload 1 375 inches 3 49 cm from body end to spring Stock Rear Spring Rear Shock Clicker 4 clicks clockwise from full soft Rear Shock Spring Preload See Optional Spring Guide page 48 Accessory Spring Recommended Initial Sett...

Page 52: ...on rider weight vehicle speed riding style and trail conditions We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The snowmobile should be methodically tested one change at a time under the same conditions trail and snow condi tions vehicle speed riding position etc after each adjustment until the best ride is achieved Break in t...

Page 53: ...nd rotate it Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension Never exceed one inch 2 54 cm of preload beyond the factory settings NOTICE When decreasing preload make sure at least two turns of preload are holding the spring between the retainer on the top of the shock and the threaded spring preload adjuster nut on th...

Page 54: ...licker counter clockwise for a softer ride When adjusting we recommend that you turn the clicker only one or two clicks then test ride Always adjust both shocks equally Shock Valving Some shocks can be revalved if spring preload alone isn t sufficient and fur ther adjustment is desired to control suspension stiffness Please see your POLARIS dealer WARNING Changing shock valving requires special to...

Page 55: ... adjust ments to one area at a time so you can evaluate the change For further assistance see 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 In deep snow a new rail slide will offer improved performance over wo...

Page 56: ...h the shock at full extension Increasing spring preload will decrease ski to ground pressure Decreasing spring preload will increase ski to ground pressure The initial preload setting is 1 375 inches 3 49 cm from body end to spring To change shock spring preload grasp the spring retainer and rotate it Increasing the spring preload too much may adversely affect the handling of the snowmo bile and t...

Page 57: ... adversely affect the han dling of the snowmobile and the performance of the suspension 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 spring between the retainer on the top of the shock and the threaded spring preload adjuster nut on the shock body Failure to do so could cause the retainer to fal...

Page 58: ... desired angle Be sure handlebars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when turned fully to the left or right If necessary loosen the set screws for the left and right controls rotate the controls slightly then tighten the set screws to the proper torque NOTICE Do not stretch wires while adjusting the controls Stret...

Page 59: ...e 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 internal engine components and exhaust systems Exhaust systems are critical safety areas that must use approved POLARIS parts Please see your POLARIS dealer for servi...

Page 60: ...s longer than the recommended length on snowmobiles 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 studded tracks are used increased wear to the brake pads will result...

Page 61: ...proper vehicle control Maintain 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 Wear strips are designed for a specific stud length See your dea...

Page 62: ...Level 91 Chaincase Oil Level 86 Injection Oil Level 73 Parking Brake Lock Brake Lever Brake System 63 64 96 Auxiliary Shut Off Switch Engine Stop Switch 66 Ignition Switch 66 Headlight Taillight Brakelight 66 Suspension Mounting Bolts 61 Skags Wear Bars 111 Ski Saddle and Spindle Bolts 61 Hood and Side Panel Fasteners 85 Throttle Lever Safety Switch 74 75 Rear Wheel Idler Bolts 107 Tether Switch S...

Page 63: ... the follow ing items on a weekly basis or before any long trip Item See Page Check suspension mounting bolts for tightness See Dealer Check rear idler wheel bolts for tightness 107 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter strap condition Check rail slide condition 112 Check track tension 106 Check ski runner skag condition 111 Check ski spindle bolts f...

Page 64: ...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 65: ... cates low brake fluid level or air in the hydraulic system Refer to the brake bleeding information on page 98 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 97 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always...

Page 66: ...to place Do not force the lock or it may break The parking brake light will illuminate if the parking brake lever lock is set while the engine is running It will also illuminate 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 tightl...

Page 67: ...nspect the track for damage before using the vehicle WARNING Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cove...

Page 68: ... 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 69: ...an 1 4 inch 6 mm open while cranking the engine When the engine starts immediately release the throttle CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running NOTICE Operating the vehicle immediately after cold starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle If...

Page 70: ...RIS products Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage Oils may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All POLARIS oils are compatible with each other Initial Fuel Premix Always premix fuel in 5 gallon 19 liter increments in a separate fuel cont...

Page 71: ...your vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the snow mobile Oil Injection System Always check and fill the oil bottle when refueling See page 73 NOTICE Serious engine damage can occur without the proper lubrication Check the oil bottle level often during the first tank of fuel If the oil level doesn ...

Page 72: ...r or snow before rotating the track 2 Use an appropriate stand to securely support the rear of the snow mobile at the rear bumper The track should be about 4 inches 10 cm off the ground 3 Start the engine and allow it to warm up two to three minutes 4 Depress the throttle abruptly and allow the track to rotate several revolutions TIP It will take longer to warm up the track sufficiently during col...

Page 73: ...in or near the area where refu eling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time The engine exhaust from this product contains chemicals known...

Page 74: ...nged 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 deicers or a...

Page 75: ...indicator light comes on 2 Open the left side panel 3 View the oil level in the oil bottle 4 Add oil as needed before operating NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refu eling Add oil as needed The oil bottle cap is vented to allow proper oil flow See your POLARIS dealer for recommended replacement p...

Page 76: ... safety 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...

Page 77: ...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 78: ...y See page 74 for more information about the engine stop switch and throttle safety switch SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch Interrupts ignition circuit Throttle Safety Switch Interrupts ignition circuit Tether Switch Option Interrupts ignition circuit ...

Page 79: ...ed Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle Look behind the vehicle before and while backing Avoid sharp turns Apply throttle slowly Electronic reverse will activate only if the engine RPM is below 4000 NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the snowmobile is in reverse Never eng...

Page 80: ... snowmobile is in reverse The maximum engine RPM will be 6000 when in reverse TIP If the engine stops running the snowmobile will be in forward gear when it s restarted Disengaging Reverse 1 Stop the snowmobile and leave the engine idling NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the snowmobile is in reverse Never engage the starter w...

Page 81: ...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 82: ...ne with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is avail able to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owne...

Page 83: ...ervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to...

Page 84: ...bricate Item 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 100 I I I Drive Belt Condition 101 I I I I Clutches 100 C C C Belt Tension I I I I Clutch Sheaves 100 I I I I ENGINE COOLING Engine Mounts 84 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 S...

Page 85: ...I I Brake System 63 96 I Brake Fluid 97 I FUEL MANAGEMENT Idle RPM I I I Throttle Lever 75 I I I I I Oil Pump Lever synchronize I I I Throttle Position Sensor I I I Fuel Lines 87 I I I I Fuel Filter Replacement 87 EVERY 2000 3200 or EVERY 2 YEARS Oil Filter 90 R Oil Lines 90 I I I Air Box I I I I I ELECTRICAL Auxiliary Shut Off Switch 66 I I I I I Throttle Safety Switch 74 I I I I I Ignition Switc...

Page 86: ... Suspension Bushings 112 I I I Suspension Shock Oil R Rear Shock Threads 85 L Cooling Fins and Shroud I I I I Skags Wear Bars 111 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 95 I I I I I Hood and Side Panel Fasteners 85 I I I I I Rear Wheel Idler Bolts 107 I I I I I Idler Bolt Jam Nut 107 I I I I I Rear Suspension Pivot Shaft 112 L L L Camber Alignment I I I Handlebar Centerin...

Page 87: ... 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 authorized POLARIS dealer Lubrication Rear Shock Body Threads Lubricate rear shock body threads seasonally with a lo...

Page 88: ...an cloth 5 Reinstall the fill plug Torque to 6 10 ft lbs 8 13 Nm Oil Change 1 Position the vehicle on a level surface 2 Place a drain pan under the drain plug Remove the drain plug Allow the oil to drain completely 3 Clean off all metal shavings from the plug TIP The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 4 Reinstall the drain plug ...

Page 89: ...ity 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 ...

Page 90: ...ection for the specific spark plug to be used in your snowmobile Use recommended spark plugs with the proper gap Use only resistor type spark plugs Torque spark plugs to 18 22 ft lbs 24 30 Nm Always carry spare spark plugs NOTICE Using non recommended spark plugs can result in serious engine damage A spark plug with a heat range too high will always cause engine damage if the engine is operated in...

Page 91: ...ench provided in the tool pouch rotate the spark plug counter clockwise to remove 4 Reverse the procedure for spark plug installation Torque to specifi cation 5 Reinstall the spark plug cap Spark Plug Condition Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range ...

Page 92: ...l Lines Inspect oil line condition every 1000 miles 1600 km 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 81 ...

Page 93: ...ixture See page 116 for POLARIS prod ucts 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 ...

Page 94: ...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 95: ... elevated at a 45 degree angle 4 Fill the coolant bottle to the COLD FILL mark 5 Using an 8mm wrench loosen the air bleed screw located on the top of the coolant outlet elbow Use a shop towel to catch any coolant that leaks from the bleeder Tighten the screw after a steady stream of coolant flows from the bleeder 6 Fill the coolant bottle to the COLD FILL mark 7 Install the coolant bottle cap to t...

Page 96: ... 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 85 2 Inspect the muffler and pipes for cracks or damage 3 Check for weak or missing retaining springs or damper support grommets 4 Check for loose clamps on the pipe covers 5 Reinstall the hood and side pan...

Page 97: ...ockwise to move all chain slack to 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 l...

Page 98: ...eath Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake 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 1 5 mm Exc...

Page 99: ...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 100: ... 2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 inch 6 8 cm below the lip of the reservoir opening Reinstall the gasket and cover 3 Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder val...

Page 101: ...acement 1 Remove the wire harness connector from the back of the headlight 2 Grasp the bulb housing and turn it counter clockwise to remove the bulb 3 Apply dielectric grease to the socket and install the new bulb Rotate the bulb 1 4 turn clockwise to secure it 4 Reinstall the connector to the back of the headlight Taillight Brake Light Replacement The taillight assembly is not serviceable If the ...

Page 102: ...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 lubri cate clutch bushings Clutch Alignment Offset Clutch al...

Page 103: ...s Replace the belt if any of these conditions exist See Drive Belt Troubleshooting on page 121 Always carry a spare drive belt Store the spare belt in the belt clip located under the left side of the hood Make sure the o ring is installed over the belt clip For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the sn...

Page 104: ...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 clock wise to increase the distance between the sheaves or outward counter clockwise to decrease the distance 3 Tighten the jam nut 1 2 ...

Page 105: ...ition 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 open far enough to remove the...

Page 106: ...fe install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as out lined in the belt removal procedures 3 Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves 4 Hold the belt down between the sheaves and roll the bottom portion o...

Page 107: ...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 108: ...e engine off NOTICE Do not use the rear bumper to lift the rear of the snowmobile for track adjustments 2 Lift the rear of the snowmobile by the chassis seat support x brace or running boards until the track is slightly above the ground Safely support the rear of the snowmobile in this position 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahe...

Page 109: ...de equal adjust ment on both sides of the track 9 Repeat the measurement on the other side of the track TIP Check more frequently when the snowmobile is new 10 Remove the weight 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 108 and adjust as necessary 12 Tighten the locknuts 13 Tighten idler...

Page 110: ...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 a...

Page 111: ...109 MAINTENANCE Steering System Front Suspension Inspection Each week or before a long ride check all steering system fasteners and tighten if necessary X X X X ...

Page 112: ...hicle weight compressing the suspension measure 10 inches 25 4 cm forward from the center of the ski mounting bolt See illustration At this point measure between the skis This is measurement X 3 Perform the same measurement rearward from the center of the ski mounting bolt This is measurement Y 4 The X measurement should be 1 8 1 4 inch 3 6 mm greater than the Y measurement If the skis are misalig...

Page 113: ...ow or ice Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter TIP Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement Some models are equipped with single skags Some models are equipped with dual skags 1 Raise and support the front of the snowmobile so the ...

Page 114: ...measures less than 7 16 inch 1 1 cm Rear Suspension Lubricate the suspension pivot shaft with Polaris All Season Grease every 1000 miles 1600 km and before seasonal storage Inspect the rear suspension bushings X at the intervals outlined in the Periodic Maintenance Table beginning on page 81 Inspect more often if the snowmobile is frequently operated in extreme conditions Replace bushings when the...

Page 115: ...ace and rinse with clean warm water For stubborn stains such as grease or oil use a citrus based cleaner 3M Citrus Base Cleaner recommended Spray onto the area to be cleaned and rub with a soft sponge Allow to sit for a couple of minutes and wash away with clean warm water Repeat as necessary to clean the surface NOTICE Never use a polishing buffing wax or any sponge that has an abrasive surface T...

Page 116: ...d 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 sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint The snowmobile should be stored in a dry garage or shed out of direct sunlight a...

Page 117: ...lizer 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 fuel Electrical Connections Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts and hot e...

Page 118: ...se 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 2871534 Polaris Antifreeze 60 40 Premix qt 95 l 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 l Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilize...

Page 119: ... drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for appli cation Replace the drive belt Clutch alignment out of spec SEE YOUR DEALER Engine mount bro ken or loose Inspect and replace SEE YOUR DEALER Machine fails to move Clutch jammed Check for twisted belt or broken spring SEE YOUR DEALER Track jammed Foreign object may be caught or the rail slide melt...

Page 120: ...YOUR DEALER Poor low RPM performance Worn drive belt Inspect and replace as needed Excessive belt sheave clearance SEE YOUR DEALER Sticky clutch SEE YOUR DEALER Poor fuel quality Use 87 91 octane fuel or higher Engine doesn t turn Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fuel supply broken parts or improper cooling Hydrostatic lock Fuel may have entered the...

Page 121: ... YOUR DEALER Engine lacks power Fouled or defective spark plug s Replace the plug s Fuel filter loss of high RPM power SEE YOUR DEALER Plugged fuel filter or tank pick up sock SEE YOUR DEALER Incorrect clutching SEE YOUR DEALER Engine continually backfires Faulty plug s Change plug s ensure caps are seated Fuel System Dirt or ice may be in the fuel system deicer should be added to non etha nol fue...

Page 122: ...rts from side to side Check ski alignment see page 110 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 Adjust rear shock spring see pages 47 and 55 Check rail slide replace if worn see page 112 Install Accu Trak dual skags see your dealer Front end pushes Check for worn skags Adjust rear shoc...

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: ...ke Type Hayes Phantom Drive Clutch Center Distance 11 5 inches 29 cm Drive Belt P N 3211122 Clutch Type P 85 Reverse Transmission Electronic Reverse Engine and Cooling Engine S4771 6044 OR6G Displacement 599 cc Cylinders 2 Bore x Stroke mm 77 25 x 64 Alternator Output 400 watt Throttle Body Mikuni Oil Injection VES Throttle Body Bore Size 46 mm Idle RPM 1700 200 Cooling Liquid Ignition Type Digita...

Page 125: ...41 72 Pitch 3000 3600 10000 12000 10 AL 1321531 120 310 Black 7043681 130 180 P2 Tab 7043873 58 42 45 P2N 5137176 20 41 72 Pitch Clutching Chart ALTITUDE Meters Feet Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase Gearing Pitch Shaded cells indicate factory settings N A INTL 0 600 0 2000 10 64 1321585 Black Green 7042083 130 180 P2 Tab 7043873 58 42 45 P2N...

Page 126: ...Type Hayes Phantom Drive Clutch Center Distance 11 5 inches 29 cm Drive Belt P N 3211115 Clutch Type P 85 Reverse Transmission Electronic Reverse Engine and Cooling Engine S4774 8044 OR8G Displacement 794 cc Cylinders 2 Monoblock Bore x Stroke mm 85 x 70 Alternator Output 400 watt Throttle Body Mikuni Oil Injection VES Throttle Body Bore Size 48 mm Idle RPM 1700 200 Cooling Liquid Ignition Type Di...

Page 127: ...43363 64 42 36 LW ER 5135401 20 38 70 Pitch 20 41 72 Pitch 3000 3600 10000 12000 10 58 1321588 140 330 7043342 LH BLK PUR TEAM LW 7043363 64 42 36 LW ER 5135401 20 38 70 Pitch 20 41 72 Pitch Clutching Chart ALTITUDE Meters Feet Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase Gearing Pitch Shaded cells indicate factory settings N A INTL 0 600 0 2000 10 66 1...

Page 128: ...of time and conditions of operation 7 Previous correspondence Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine POLARIS Customer Service United States 1 888 704 5290 Canada 1 204 925 7100 POLARIS Anti Theft System The POLARIS anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles...

Page 129: ... 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 trailer transit or as a result of unauthorized service or parts In add...

Page 130: ...to Obtain Warranty Service If your snowmobile requires warranty service you must take it to a POLARIS dealer authorized to repair POLARIS snowmobiles When requesting warranty service you must 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 ...

Page 131: ... coverage 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 contami...

Page 132: ... s authorized location This policy does not apply to Safety Bulletins How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your vehicle was purchased War ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells ...

Page 133: ...otices regarding your vehicle If Purchased From A Private Party If you purchase a POLARIS product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and...

Page 134: ... components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the followi...

Page 135: ...d by a defect in material or workman ship 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...

Page 136: ...er each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km ...

Page 137: ...135 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 138: ...136 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 139: ...t Level 91 Cooling System 91 93 Cooling System Bleeding 93 Cooling System Flushing 92 Customer Service 126 D DET 28 29 Detonation Elimination 28 29 Diagnostic Display Codes 44 45 Diagnostic Display Mode 43 Disabled Operators 12 Display Standard Metric 36 Drive Belt Break In 69 Adjustment 102 Condition 101 Deflection 102 Installation 104 Removal 103 Drive Chain Tension 95 Driver Awareness 14 Drives...

Page 140: ...pection Pre Ride 60 Instrument Cluster 30 45 Intake Filters 87 Intake Silencer 18 L Lights Headlight Replacement 99 Taillight Brake Light 99 Lubrication 85 86 M Maintenance Interval Table 82 84 Maintenance Program 81 Maintenance Recommendations 9 Maneuverability 18 Matte Finish Cleaning 113 Metric Standard Display 36 N Noise 6 O Odometer Engine Hour Display 35 Oil Change Chaincase 86 Oil Filter 90...

Page 141: ...e Engine Restarting 67 Steering System 109 112 Steering System Inspection 65 Stopping Emergency 76 Storage Procedures 114 115 S Storage Daily 79 Studs 58 Survival Preparation 12 Suspension Adjustments Front 50 52 Suspension Adjustments Rear 53 55 Suspension Inspection Pre Ride 61 Suspension Inspection Rear 112 Suspension Performance Tips 53 Suspension Quick Set Up Guide 46 49 Switches Engine Stop ...

Page 142: ...For your nearest Polaris dealer call 1 800 POLARIS or visit www polaris com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9924269 Rev 01 Printed in USA PMS 419 9924269 ...

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