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TROUBLESHOOTING

Engine Troubleshooting

Unless you have experience and training in two-cycle engine repair, see
your dealer if technical problems arise.

Problem

Probable Cause

Solution

Erratic engine
operating RPM
during acceleration
or load variations

Drive clutch binding

• SEE YOUR DEALER.

Driven clutch
malfunction

• SEE YOUR DEALER.

Harsh drive clutch
engagement

Drive belt worn or
too narrow

• Replace the drive belt.

Excessive belt/
sheave clearance

• SEE YOUR DEALER.

Drive belt turns over

Wrong belt for
application

• Replace the drive belt.

Clutch alignment out
of spec

• SEE YOUR DEALER.

Engine mount
broken or 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 melted to the track clips
due to lack of lubrication.

• Track may be iced up or frozen to

the ground.

Chaincase sprocket
or chain jammed or
broken

• Chain is loose or broken or chain

tightener is loose. SEE YOUR
DEALER.

Содержание 2015 AXYS 600 RUSH

Страница 1: ...Snowmobile Owner s Manual for Maintenance and Safety 2015 600 800 RUSH 2015 600 800 SWITCHBACK...

Страница 2: ...tions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product cont...

Страница 3: ...recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever pr...

Страница 4: ...ion presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reus...

Страница 5: ...nd features The Perfect Fit 51 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 6...

Страница 6: ...4...

Страница 7: ...re 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...

Страница 8: ...at snowmobiles conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered o...

Страница 9: ...ht side of tunnel ____________________________________________ Engine Serial Number on recoil housing _____________________________________ Key Number _________________________________________________...

Страница 10: ...gnition keys are etched with an identification number Remove the spare key and store it in a safe place Your key can be duplicated only by mating a POLARIS key blank using the same identification numb...

Страница 11: ...us situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION...

Страница 12: ...in excellent operating condition at all times Always check major and vital safety components before every ride All POLARIS snowmobiles are designed and tested to provide safe operation when used as d...

Страница 13: ...e running Stop the engine before opening a side panel Always ensure that the hood and side panels are installed and securely latched before starting the engine WARNING Serious injury can occur if fing...

Страница 14: ...r will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterpro...

Страница 15: ...If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the conditions you may encounter Such equipment may include but is...

Страница 16: ...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 y...

Страница 17: ...lf a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Never travel on frozen bodies of water unless you have first ve...

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

Страница 19: ...rating 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...

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

Страница 21: ...complex mechanism that rotates at high speeds Each clutch is dynamically balanced before installation Any tampering may disrupt this precision balancing and create an unstable condition Cold Weather D...

Страница 22: ...ll as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of...

Страница 23: ...50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min 5 min W...

Страница 24: ...ble or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label Pressure Cap Warning This...

Страница 25: ...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 Appl...

Страница 26: ...g 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 sp...

Страница 27: ...lt removed Never service clutches yourself See your dealer Belt Removal All Units 1 For electric reverse models engine must be stopped in forward to allow clutch opening 2 Install L wrench from fender...

Страница 28: ...ront 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 Insid...

Страница 29: ...hown 3 Ignition 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 POLARIS Electronic Reverse PERC Butto...

Страница 30: ...stance from the floor to the center of the headlight and make a mark on the wall at the same height 4 Start the engine Move the headlight switch to high beam 5 Observe the headlight aim on the wall Th...

Страница 31: ...tment can be used to warm gloves or defog goggles 12 Volt Receptacle If equipped the 12 volt DC receptacle is located on the console next to the instrument cluster If not equipped the receptacle can b...

Страница 32: ...n other models Please see your POLARIS dealer for more information Three 3 locking plungers secure each saddlebag to the rear cargo rack To remove a saddlebag open each plunger latch then pull the bag...

Страница 33: ...al display IDD please see your IDD Owner s Manual for fuel type selection procedures Standard Instrument Cluster Use the following procedure to change the fuel type designation in the standard instrum...

Страница 34: ...quired The engine will return to its normal performance automatically If severe detonation occurs the check engine light will begin to flash steadily The standard gauge will display dET The IDD will d...

Страница 35: ...hanol non ethanol fuel type setting Verify correct fuel type setting on gauge Low fuel no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel filter or t...

Страница 36: ...re indicator at the top left of the screen illuminates when the engine is overheating Take action to cool the engine See page 35 The indicator will flash when engine temperature reaches critical level...

Страница 37: ...stem Ignition Lock System Your snowmobile has an optional security function that can be activated by an authorized POLARIS dealer If you have this feature activated you can lock the ignition to preven...

Страница 38: ...Certain products will damage the lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Immediately clean off any gasoline that splashes on the instrument cluster CAUTION T...

Страница 39: ...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 bo...

Страница 40: ...resettable trip meters 2 total engine hours of operation fuel level engine temperature and diagnostic display mode Setting changes must be made with the engine running or with the vehicle powered by a...

Страница 41: ...tank 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...

Страница 42: ...m displays first make sure the information display area is set to display either engine speed or vehicle speed 2 Press and hold the MODE button on the instrument cluster or the MODE switch on the left...

Страница 43: ...ayed 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 spe...

Страница 44: ...nits 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 MO...

Страница 45: ...is feature activated you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended A locked system will limit engine speed to 3000 RPM which prevents clutch engagement a...

Страница 46: ...uttons 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...

Страница 47: ...ystem 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 O...

Страница 48: ...t digit 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 ac...

Страница 49: ...it When 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...

Страница 50: ...System 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...

Страница 51: ...active 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...

Страница 52: ...tch on the left handlebar Please see your IDD Owner s Manual for more information NOTICE Use a microfiber hand towel to clean the LCD screen Certain products will damage the screen and other plastic s...

Страница 53: ...k spring preload or decrease the front track spring preload If you prefer your snowmobile has lighter steering decrease the rear track spring preload or increase the front track shock spring preload A...

Страница 54: ...r track shock spring preload OR Increase front track shock spring preload Front Suspension IFS Shocks Too Stiff Too Soft IFS Shocks Turn clickers 2 clicks SOFT Turn clickers 2 clicks HARD Ride Comfort...

Страница 55: ...Setting Spring Part Number lb in N mm in cm in cm in cm RUSH PRO S 80 14 2 1 2 6 4 2 1 2 6 4 3 1 2 8 9 7043732 RUSH PRO X 100 17 5 4 1 2 11 4 4 1 2 11 4 4 3 4 12 7041576 SWITCHBACK PRO S 80 14 2 1 2 6...

Страница 56: ...54 THE PERFECT FIT Suspension Quick Set Up Guide Front IFS Shock Adjustments SOFTER TALLER STIFFER LOWER M E A S U R E H E R E...

Страница 57: ...ting Spring Part Number lb in N mm in cm in cm in cm RUSH PRO S 95 280 16 6 49 1 1 2 3 8 1 1 2 3 8 1 85 4 7 7043957 RUSH PRO X 150 26 1 2 54 1 2 54 1 1 4 3 17 7043678 SWITCHBACK PRO S 95 280 16 6 49 1...

Страница 58: ...56 THE PERFECT FIT Suspension Quick Set Up Guide Front Track Shock Adjustments SOFTER MEASURE HERE STIFFER MORE LITE MORE BITE...

Страница 59: ...USH PRO S 120 21 2 3 4 7 2 5 3 1 2 8 9 7041575 RUSH PRO X 150 26 1 1 2 3 8 1 2 1 2 2 1 2 6 4 7043160 SWITCHBACK PRO S 120 21 2 3 4 7 2 5 3 1 2 8 9 7041575 SWITCHBACK PRO X 150 26 1 1 2 3 8 1 2 1 2 2 1...

Страница 60: ...58 THE PERFECT FIT Suspension Quick Setup Guide Rear Track Shock Adjustments SOFTER MEASURE HERE STIFFER MORE LITE MORE BITE...

Страница 61: ...miter strap length at position 1 to maintain the optimum ride characteristics of the snowmobile Riders who desire less ski pressure and more weight transfer toward the rear of the snowmobile can lengt...

Страница 62: ...eference Factory settings are shown below 1 Loosen the four bolts on the bottom of the adjuster block If necessary pry the blocks apart with a screwdriver 2 Adjust the riser forward or rearward to the...

Страница 63: ...r 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...

Страница 64: ...r Master Cylinder 70 in lbs 7 9 Nm 3 Hand Guard Mounts if applicable Hand Tight 4 Upper Lower Riser Clamps 14 8 ft lbs 20 Nm 5 Auxiliary Engine Stop Switch Set Screw 12 in lbs 1 4 Nm 6 Throttle Lever...

Страница 65: ...Refer to the following illustration and measurements to position handlebar components at factory specified locations Handlebar Component Alignment Measurements 1 011 in 3 mm 2 6 65 in 169 mm 3 6 7 in...

Страница 66: ...e reduced on hard packed snow or ice When studded tracks are used increased wear to the brake pads will result from increased braking and requires increased brake inspection intervals Installing studs...

Страница 67: ...ering and control See page 125 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 you...

Страница 68: ...Chaincase Oil Level 98 Injection Oil Level 80 Parking Brake Lock Brake Lever Brake System 69 70 110 Auxiliary Shut Off Switch Engine Stop Switch 72 Ignition Switch 72 Headlight Taillight Brake Light...

Страница 69: ...the following 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 121 Check rear idler ad...

Страница 70: ...l Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience Throttle Lever The throttle and brake are the primary controls of your...

Страница 71: ...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 111 WARNING Continued use of spongy brakes...

Страница 72: ...o 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...

Страница 73: ...ure which could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle WARNING Use of traction products such as studs increases the pos...

Страница 74: ...ch down to stop the engine Pull it up to allow restarting Ignition Key Switch Make sure the engine stops when the ignition key switch is turned to OFF Tether Switch if equipped If your snowmobile has...

Страница 75: ...e The IDD is not dependent on the battery while the engine is running but the battery supplies a constant power source when the engine is turned off or when the engine is transitioning between forward...

Страница 76: ...re than 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 ro...

Страница 77: ...IS 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 forma...

Страница 78: ...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 snowmobile Oil Injection System Always check and fill...

Страница 79: ...or snow before rotating the track 2 Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper The track should be about 4 inches 10 cm off the ground 3 Start the engi...

Страница 80: ...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...

Страница 81: ...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 r...

Страница 82: ...ght comes on 2 Open the left side panel See page 94 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...

Страница 83: ...lty throttle release switch can result in serious injury or death in the event of an accident If the throttle release switch does not shut off the engine during a throttle system malfunction immediate...

Страница 84: ...rough normal starting procedures 5 If the engine doesn t start take the snowmobile to an authorized POLARIS dealer for service Throttle Lever Freeplay Inspection Throttle lever freeplay is the gap cre...

Страница 85: ...clockwise to INCREASE freeplay 4 When freeplay is adjusted to 009 029 in 0 25 0 76 mm tighten the lock nut against the adjuster 5 Start the engine and allow it to idle 6 Turn the handlebar to the full...

Страница 86: ...dle speed 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 Electro...

Страница 87: ...the 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 t...

Страница 88: ...tow hitch on the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between t...

Страница 89: ...e with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specificat...

Страница 90: ...rvals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registered owner If during the course of the warranty period...

Страница 91: ...necessary C Clean R Replace L Lubricate Item See Page Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 114 I I I Drive Belt...

Страница 92: ...outing I I I I Hose Condition I I I I Fluid Leaks I I I I Brake Pads 110 I I I I Brake Disc I I I I Parking Brakes 70 I I I I Brake System 69 110 I Brake Fluid 111 I FUEL MANAGEMENT Throttle Lever 82...

Страница 93: ...Steering Fasteners I I I I C Rear Suspension Fasteners I I I I I Suspension Shock Oil R Rear Shock Threads 98 L Skags Wear Bars 125 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 109...

Страница 94: ...ge 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 To...

Страница 95: ...20194 3 Voltage Too Low 4 Throttle Stuck 7 Chassis Relay Driver Circuit Open Grounded 520208 5 Driver Circuit Short to B 3 Exhaust Valve Solenoid 600 Only Driver Circuit Grounded 520215 5 Driver Circu...

Страница 96: ...ecurely latched before starting the engine Side Panels Opening Removing To open a side panel rotate the two 1 4 turn fasteners at the upper edges of the side panel Release the strap at the lower edge...

Страница 97: ...Disconnect the wire harness leading to the console electronics 4 Remove the hood assembly 5 To reinstall the hood slide the nose clips into the nosepan 6 Position the hood and align the 1 4 turn faste...

Страница 98: ...wrench rotate it counter clockwise and slide it upward from the bracket When it s not in use return the L wrench to the bracket and rotate it clockwise The tool kit is stored in a container attached t...

Страница 99: ...ontainer is positioned slightly higher than the front loop 6 Slide the container into the engine compartment at an angle 7 Position the container bracket onto the bumper tube and rotate it downward 8...

Страница 100: ...c Maintenance Table beginning on page 88 Maintain the oil level at the top of the fill plug hole POLARIS recommends the use of Synthetic Chaincase Lubricant See page 137 for the part numbers of POLARI...

Страница 101: ...shavings off the plug 3 Insert the tube of a hand pump oil extractor into the fill hole Direct the hose toward the bottom front area of the cover away from the chain sprocket 4 Extract the oil from th...

Страница 102: ...he BLACK cable first and then disconnect the RED cable last 4 Place a drain pan under the chaincase 5 Loosen do not remove the chaincase cover screws 6 Carefully pry the cover open NOTICE DO NOT inser...

Страница 103: ...poor quality fuel may shorten the life of fuel system components and result in poor engine performance Always store fuel in clean fuel containers If low fuel pressure or reduced engine performance oc...

Страница 104: ...ENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system When operating in loose powder snow check the foam filters periodically to remove any accumulation of snow Foa...

Страница 105: ...Maintenance Table beginning on page 88 Use the recommended spark plugs with the proper gap Refer to the specifications section beginning on page 142 Use only resistor type spark plugs Torque spark pl...

Страница 106: ...kit rotate the spark plug counter clockwise to remove it 4 Reverse the procedure for spark plug installation Torque to specification 5 Reinstall the spark plug cap Verify and audible click is heard wh...

Страница 107: ...RIS products 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 contro...

Страница 108: ...function properly If the pressure cap needs replacement contact your dealer for the correct part NOTICE Severe engine damage may occur if the cooling system becomes restricted or plugged or contains...

Страница 109: ...fast idle for several minutes until the heaters are warm to the touch Loosen the bleed screw occasionally to purge any trapped air 10 When all heater extrusions are warm to the touch stop the engine 1...

Страница 110: ...ot 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 2 Inspect the...

Страница 111: ...m to cool Never perform this procedure with the engine running 1 Remove the side panels 2 Rotate the driven clutch counter clockwise to move all chain slack to the tensioner side 3 Lock the parking br...

Страница 112: ...ke 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...

Страница 113: ...nt slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function NOTICE Brake fluid will damage labels paint and s...

Страница 114: ...reservoir vent 1 Remove the brake master cylinder reservoir cover and gasket 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 reservo...

Страница 115: ...light and taillight assemblies feature LED elements and are not serviceable If an LED fails to illuminate in either the headlight or taillight the entire assembly must be replaced Please see your POLA...

Страница 116: ...epairs 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 w...

Страница 117: ...s Replace the belt if any of these conditions exist See Drive Belt Troubleshooting on page 162 Always carry a spare drive belt Store the spare belt in the belt holder as shown When placing the belt in...

Страница 118: ...ownward pressure while measuring at point 2 This measurement should be 1 1 4 inches 3 2 cm Drive Belt Deflection Adjustment 1 Loosen the 11 mm jam nut on the belt width adjuster 2 Using a 3 mm Allen w...

Страница 119: ...gine after operating in a forward motion 2 Turn the ignition key off Wait for the engine to come to a complete stop 3 Lock the parking brake 4 Remove the left side panel 5 Rotate the driven clutch cou...

Страница 120: ...should be flush with or slightly above the outer circumference of the driven clutch sheaves 3 Hold the belt down between the sheaves and roll the bottom portion over the outer clutch sheave Work the b...

Страница 121: ...ow 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 insuffici...

Страница 122: ...up and limber Stop the engine 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 runni...

Страница 123: ...tment 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 or if studs are installed 10 Remove the weight Start the e...

Страница 124: ...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 t...

Страница 125: ...sulting in serious injury or death See your POLARIS dealer Each week or before a long ride check the following items If component damage or loose fasteners are found see your POLARIS dealer for servic...

Страница 126: ...pt to change toe adjustment See your POLARIS dealer The skis on your snowmobile are set with a small amount of toe out at the factory You can inspect the toe setting by following the procedure below I...

Страница 127: ...now or ice Check skags before each use of the snowmobile to ensure positive steering characteristics Skags must be replaced when worn to half their original diameter TIP Carbide skags must be replaced...

Страница 128: ...allow for adjustment to compensate for bushing wear NOTE Upper control arm shown Procedure is the same for lower control arm adjustment 1 Loosen the four lock nuts 2 From the bushing side of each pivo...

Страница 129: ...esulting in serious injury or death See your POLARIS dealer Each week or before a long ride check the following items If component damage or loose fasteners are found see your POLARIS dealer for servi...

Страница 130: ...slide thickness at several points along the rail Have your dealer replace the slide when it s worn down to the top of the wear limit indicator groove Do not operate the snowmobile if slide thickness...

Страница 131: ...lack cable last Battery Removal CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running 1 Remove the ri...

Страница 132: ...sis 8 Remove the battery shield 5 9 Pull the fender away from the battery compartment and remove the battery 10 With the battery removed from the snowmobile the battery bracket can be removed to acces...

Страница 133: ...negative cable last 8 Verify that cables are properly routed 9 Install the battery shield Tighten the shield screw Torque 7 ft lbs 10 Nm 10 Install the right fender using the plastic rivet 11 Reinstal...

Страница 134: ...battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The sin...

Страница 135: ...ry 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 Tip Always ver...

Страница 136: ...ase 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 N...

Страница 137: ...tion with waxes and rust inhibitors grease oil or 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...

Страница 138: ...izer 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 t...

Страница 139: ...SCL Synthetic Chaincase Lubricant gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season 3 oz 89 ml 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 41...

Страница 140: ...es 26 97cm Drive Belt Type Projected Width PBO Double Cog Cut Finish 1 46 inches 3 7 cm Drive Driven Clutches P 85 Team LWT Reverse POLARIS Electronic Reverse Control PERC Front Rear Travel 9 3 in 23...

Страница 141: ...10 62 1321586 1200 1800 4000 6000 10 60 1321587 1800 2400 6000 8000 10 58 1321588 2400 3000 8000 10000 10 56 1321684 21 42 70 3000 3600 10000 12000 10A L 1321531 NOTE Use 2 gram lighter shift weights...

Страница 142: ...25 inches 26 97cm Drive Belt Type Projected Width PBO Double Cog Cut Finish 1 46 inches 3 7 cm Drive Driven Clutches P 85 Team LWT Reverse POLARIS Electronic Reverse Control PERC Front Rear Travel 9 9...

Страница 143: ...00 1200 2000 4000 10 62 1321586 1200 1800 4000 6000 10 60 1321587 1800 2400 6000 8000 10 58 1321588 2400 3000 8000 10000 10 56 1321684 21 42 70 3000 3600 10000 12000 10A L 1321531 NOTE Use 2 gram ligh...

Страница 144: ...ce 10 625 inches 26 97cm Drive Belt Type Projected Width PBO Double Cog Cut Finish 1 46 inches 3 7 cm Drive Driven Clutches P 85 Team LWT Reverse POLARIS Electronic Reverse Control PERC Front Rear Tra...

Страница 145: ...62 1321586 1200 1800 4000 6000 10 60 1321587 1800 2400 6000 8000 10 58 1321588 2400 3000 8000 10000 10 56 1321684 21 42 70 3000 3600 10000 12000 10A L 1321531 NOTE Use 2 gram lighter shift weights whe...

Страница 146: ...Distance 10 625 inches 26 97cm Drive Belt Type Projected Width PBO Double Cog Cut Finish 1 46 inches 3 7 cm Drive Driven Clutches P 85 Team LWT Reverse POLARIS Electronic Reverse Control PERC Front R...

Страница 147: ...1200 2000 4000 10 62 1321586 1200 1800 4000 6000 10 60 1321587 1800 2400 6000 8000 10 58 1321588 2400 3000 8000 10000 10 56 1321684 21 42 70 3000 3600 10000 12000 10A L 1321531 NOTE Use 2 gram lighte...

Страница 148: ...ance 10 625 inches 26 97cm Drive Belt Type Projected Width PBO Double Cog Cut Finish 1 46 inches 3 7 cm Drive Driven Clutches P 85 Team LWT Reverse POLARIS Electronic Reverse Control PERC Front Rear T...

Страница 149: ...00 10 62 1321586 1200 1800 4000 6000 10 60 1321587 1800 2400 6000 8000 10 58 1321588 2400 3000 8000 10000 10 56 1321684 21 42 70 3000 3600 10000 12000 10A L 1321531 NOTE Use 2 gram lighter shift weigh...

Страница 150: ...er Distance 10 625 inches 26 97cm Drive Belt Type Projected Width PBO Double Cog Cut Finish 1 46 inches 3 7 cm Drive Driven Clutches P 85 Team LWT Reverse POLARIS Electronic Reverse Control PERC Front...

Страница 151: ...00 2000 4000 10 62 1321586 1200 1800 4000 6000 10 60 1321587 1800 2400 6000 8000 10 58 1321588 2400 3000 8000 10000 10 56 1321684 21 42 70 3000 3600 10000 12000 10A L 1321531 NOTE Use 2 gram lighter s...

Страница 152: ...inches 26 97cm Drive Belt Type Projected Width High Modulus PBO Double Cog Cut Finish 1 46 inches 3 7 cm Drive Driven Clutches P 85 Team LWT Reverse POLARIS Electronic Reverse Control PERC Front Rear...

Страница 153: ...4000 6000 10 62 1321586 1800 2400 6000 8000 10 60 1321587 Black 7043063 2400 3000 8000 10000 140 330 7043829 20 39 68 3000 3600 10000 12000 10 58 1321588 NOTE Use 2 gram lighter shift weights when op...

Страница 154: ...inches 26 97cm Drive Belt Type Projected Width High Modulus PBO Double Cog Cut Finish 1 46 inches 3 7 cm Drive Driven Clutches P 85 Team LWT Reverse POLARIS Electronic Reverse Control PERC Front Rear...

Страница 155: ...200 1800 4000 6000 10 62 1321586 1800 2400 6000 8000 10 60 1321587 Black 7043063 2400 3000 8000 10000 140 330 7043829 21 42 70 3000 3600 10000 12000 10 58 1321588 NOTE Use 2 gram lighter shift weights...

Страница 156: ...5 inches 26 97cm Drive Belt Type Projected Width High Modulus PBO Double Cog Cut Finish 1 46 inches 3 7 cm Drive Driven Clutches P 85 Team LWT Reverse POLARIS Electronic Reverse Control PERC Front Rea...

Страница 157: ...0 1800 4000 6000 10 62 1321586 1800 2400 6000 8000 10 60 1321587 Black 7043063 2400 3000 8000 10000 140 330 7043829 20 39 68 3000 3600 10000 12000 10 58 1321588 NOTE Use 2 gram lighter shift weights w...

Страница 158: ...625 inches 26 97cm Drive Belt Type Projected Width High Modulus PBO Double Cog Cut Finish 1 46 inches 3 7 cm Drive Driven Clutches P 85 Team LWT Reverse POLARIS Electronic Reverse Control PERC Front...

Страница 159: ...00 6000 10 62 1321586 1800 2400 6000 8000 10 60 1321587 Black 7043063 2400 3000 8000 10000 140 330 7043829 21 42 70 3000 3600 10000 12000 10 58 1321588 NOTE Use 2 gram lighter shift weights when opera...

Страница 160: ...drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for application Replace the drive belt Clutch alignment out of spec SEE YOUR DEALER Engine mount broken or l...

Страница 161: ...OUR 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...

Страница 162: ...ne 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 Y...

Страница 163: ...s 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 57 and 58 Check rail slide...

Страница 164: ...the gear ratio Reduce RPM Avoid 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 o...

Страница 165: ...this manual Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following informati...

Страница 166: ...d by POLARIS including but not limited to Two year extended engine coverage Two year powertrain coverage Extended service contract See your dealer for details and separate terms and conditions for any...

Страница 167: ...components use of aftermarket components unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial pur...

Страница 168: ...AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR I...

Страница 169: ...he selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another coun...

Страница 170: ...tside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than s...

Страница 171: ...omponents of systems if their only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This Emissions Limite...

Страница 172: ...or workmanship This Limited Warranty does not cover damage due to accidents abuse or improper handling maintenance or use This Limited Warranty also does not cover any engine that has been structurall...

Страница 173: ...r each time your snowmobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED...

Страница 174: ...172 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Страница 175: ...173 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Страница 176: ...vice 163 D DET 32 33 Diagnostic Display Codes 92 93 Diagnostic Display Mode 49 Disabled Operators 13 D Drive Belt Adjustment 116 Break In 76 Condition 115 Deflection 116 Installation 118 Removal 117 S...

Страница 177: ...splay 42 O Odometer Engine Hour Display 41 Oil Change Chaincase 99 101 Oil Injection System 76 Oil Level Chaincase 98 Oil Level Injection 80 Oil Recommendations 75 Operating in Deep Snow 17 Operator S...

Страница 178: ...nt 126 Suspension Inspection Pre Ride 67 Suspension Inspection Rear 127 Suspension Quick Set Up Guide 51 59 Suspension Rear 127 128 Switches Engine Stop Switch 81 Ignition Switch 73 Mode Select Button...

Страница 179: ...For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Industries Inc 2100 Hwy 55 Medina MN 55340 Part No 9925073 Rev 01 Printed in USA 9925073...

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