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• Page 2
  Pantone 425C For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922596 Rev 01 Printed in USA…
• Page 3
  Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
• Page 4
  The text is printed on 100% recycled with 40% post-consumer waste (PCW).
• Page 5
  ® • Victory Motorcycles ® We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
• Page 6
  POLARIS and THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result between the actual vehicle and the information presented in this publi- cation.

• Page 7: Table Of Contents

  Polaris Products….. . . 116 Troubleshooting ….. . . 117 Warranty .

• Page 9: Introduction

  INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations.

• Page 10: Preservation Of The Environment

  Polaris snowmobiles are engineered to conform to these SAE standards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others.

• Page 11: Vehicle Identification Numbers

  Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

• Page 12: Safety

  SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

• Page 13: Operator Safety

  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 opera- tion with any modifications, especially those that increase speed or power. DO NOT MODIFY YOUR MACHINE.

• Page 14
  SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. WARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track.

• Page 15: Survival Preparation

  Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.

• Page 16: Eye Protection

  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.

• Page 17: Rider Capacity

  SAFETY Operator Safety Rider Capacity Your snowmobile is designed for up to two riders. A decal on the console indicates that the vehicle is designed for one operator and one passenger only. WARNING! Operating improperly with a passenger could cause loss of control and result in serious injury or death.

• Page 18: Cargo Capacity

  SAFETY Operator Safety Cargo Capacity See page 32 for cargo loading information. WARNING! Overloading the cargo carrier can cause loss of control resulting in severe injury or death. The maximum cargo carrier capacity is 75 lbs. (34 kg). Never exceed the cargo carrier capacity. Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills.

• Page 19: Excessive Speed

  SAFETY Operator Safety Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile opera- tion and speed limits.

• Page 20: Driver Awareness

  SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts.

• Page 21
  Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • Take an avalanche class • Travel with experienced people • Travel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon.

• Page 22: Driving Downhill

  SAFETY Operator Safety Ice and Snow Build-up WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering.

• Page 23: Driving On Slippery Surfaces

  SAFETY Operator Safety Driving on Slippery Surfaces WARNING! Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard- packed snow reduces steering and braking control, which may result in loss of control and serious injury or death.

• Page 24: Drive Belt

  SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. CAUTION! Operation of the engine with the belt removed may result in personal injury or damage to the engine. Any servicing that requires operation without a belt must be performed by your dealer.

• Page 25: Operating In Deep Snow

  SAFETY Operator Safety 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.

• Page 26: Driving Responsibly

  SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile condi- tions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned driv- ers should spend some time getting the feel for a machine before attempting ambitious maneuvers.

• Page 27
  Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WIND CHILL CHART (°F) Wind Speed Calm Frostbite in >> 30 min. WIND CHILL CHART (°C) Wind Speed Calm -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69…

• Page 28: Clutch Warning

  If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.

• Page 29: Passenger Warning

  Safety Decals and Locations Passenger Warning Snowmobiles designed for an operator and one passenger have a warn- ing decal on the console. For more information on operating with a pas- senger, see page 13. WARNING This vehicle is designed for operator and “ONE” passenger only. Track Warning WARNING Stay clear of track.

• Page 30: Reverse Warning

  Safety Decals and Locations Reverse Warning Reverse Warning Polaris snowmobiles equipped with standard reverse and will have this decal on the console: WARNING Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always: •…

• Page 31: Operation Warning

  Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all Polaris snowmobiles: WARNING • To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If manual is missing, con- tact a Polaris dealer for a replacement.

• Page 32: Features

  FEATURES 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. Windshield 7. Mountain Bar 8. Handlebar 9. Fuel Filler Cap 10. Seat 11. Backrest 12. Taillights 13. Cargo Carrier 14. Rear Bumper 15. Snow Flap 16. Track 17.

• Page 33: Features

  1. Glove Box 2. MFD Display 3. Ignition Switch 4. 12-Volt DC Outlet 5. Shifter 6. Work Light Switch 7. Brake Lever 8. Handlebar Grip Warmer 9. Thumbwarmer Switch 10. Throttle Control 11. Engine Stop Switch 12. Electronic Reverse Button 13.

• Page 34: Features

  FEATURES Backrest The backrest is adjustable for either operator or passenger use. 1. Loosen the upper adjustment knobs to raise or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest for- ward for operator use or rear- ward for passenger use.

• Page 35: Features

  Adjustable Headlights Move the headlight adjuster to raise or lower the headlight beam. • Move the adjuster to the left to lower the beam. • Move the adjuster to the right to raise the beam. Glove Box The glove box is a heated dry storage area intended for drying wet gloves.

• Page 36: Features

  FEATURES Cargo Carrier WARNING! Overloading or towing improperly can alter vehicle handling and can cause loss of control. • Do not exceed the cargo carrier capacity. • Always reduce speed and allow greater distance for braking and turning when carrying cargo or a passenger, or when towing.

• Page 37: Features

  Passenger Grab Handle The position of the passenger grab handles can be adjusted for rider preference. 1. Remove the adjustment bolt. 2. Reposition the grab handles to one of the two adjustment positions on the grab handle tube between the operator seat and the passenger seat.

• Page 38: Features

  Verify correct fuel resistor for fuel type in tank Refuel with recommended fuel Replace with recommended fuel See your Polaris dealer for service Do not add de-icers or additives that contain any form of alcohol while using up to 10% ethanol fuel…

• Page 39: Features

  Instrumentation MFD Component Identification Item 1 Analog Gauge (if equipped) 2 Digital Gauge 3 Check Engine Indicator 4 High Temp Indicator 5 Brake Indicator 6 Reverse Indicator 7 High Beam Indicator Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage Level…

• Page 40: Features

  FEATURES Instrumentation MFD Settings The MFD control switch allows you to set the MFD display to your pref- erences. The rocker switch has a MODE button (top) and a SET but- ton (bottom). Specific instructions are outlined on the following pages. MFD settings can be made with the engine running or with the engine off.

• Page 41: Features

  Instrumentation MFD Settings Speedometer/Tachometer If your model is equipped with both analog and digital displays, the speedometer and tachometer can be viewed in either display. If the ana- log display is set to show speedometer readings, the digital screen will automatically display the tachometer (option 1).

• Page 42: Features

  FEATURES Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD pro- grams: Performance, Engine and History. Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycle through the program’s screens.

• Page 43: Features

  FEATURES Instrumentation MFD Digital Display Programs Performance Program Trip Settings Trip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge. The fuel symbol and the last fuel bar on the MFD gauge (if equipped) will blink when the fuel level reaches 1/8 of a tank.

• Page 44
  FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting (if equipped) 1. Enter the Performance Program. 2. Press and release the SET button until the clock screen is active. 3. Press and hold the SET button for five seconds. 4.

• Page 45: Features

  Instrumentation MFD Digital Display Programs Engine Program Press and release the MODE button until the engine program screen is active. The default display for this screen includes engine hours, electri- cal system voltage level, fuel level (if equipped) and either engine cool- ant temperature, air temperature (accessory) or altimeter (accessory).

• Page 46: Features

  FEATURES Instrumentation MFD Digital Display Programs Engine Program Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. 1. Enter the Engine Program. Tip: Press and hold the MODE switch for ten sec- onds to switch between standard and metric units of measurement.

• Page 47: Features

  Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active. This screen will always display electrical system voltage level and fuel level (if equipped). Press and release the SET button to cycle through the Maximum Vehicle Speed, Maximum Engine RPM and Service Interval Reminder screens.

• Page 48: Features

  FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due.

• Page 49: Features

  Instrumentation MFD Digital Display Programs History Program Service Interval Reminder To reset the reminder at a new interval: 1. Enter the History Program. 2. Press and release the SET button until the service interval screen is active. 3. Press and hold the SET button for five seconds, until the hours begin to flash.

• Page 50: Features

  FEATURES Instrumentation MFD Battery Replacement Models equipped with the clock feature have a battery to power the clock. If the clock function of the MFD isn’t working properly, replace the battery. Replace- ment batteries are available from your dealer. 1. Remove the plenum from the under- side of the hood.

• Page 51: Features

  Instrumentation MFD Battery Replacement 5. Using needle-nose pliers, grasp the battery and rotate it so the lead- ing edge of the battery is raised away from the battery holder. Pull the battery out gently. Tip: The battery will not come out of the holder unless the leading edge of the battery is raised.

• Page 52: The Perfect Fit

  Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris dealer for assistance before attempt- ing to adjust preload. Increasing the spring preload too much may adversely affect the han- dling of the snowmobile and the performance of the rear suspension.

• Page 53: Suspension Performance Tips

  • In deep snow, a new rail slide will offer improved performance over a worn slide. It can also improve top speed. • Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. Tip: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.

• Page 54: Rear Suspension Adjustments

  THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the dis- tance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension.

• Page 55: Torsion Spring Preload

  Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. This adjustment is easier to make if tension is relieved from the spring. Exercise extreme caution if you use this method of adjustment, and follow the steps below carefully.

• Page 56
  THE PERFECT FIT Rear Suspension Adjustments Limiter Strap Position (Ski Pressure) The following information is provided only as a guideline to High be used for initial suspension set-up. Your set-up may vary based on your desired riding style. High: Limiter strap in high position increases ski pressure Low: Limiter strap in low position decreases ski pressure…
• Page 57
  THE PERFECT FIT Rear Suspension Adjustments Shock Compression Valving The rear track shocks for this model are gas charged shocks. The valv- ing on the gas charged shocks is pre-set.

• Page 58: Handlebar Adjustments

  THE PERFECT FIT Handlebar Adjustments Use the following steps to adjust handlebar angle at the handlebar block. 1. Remove the mountain bar. 2. Remove the handlebar cover. 3. Using a 7/16″ wrench, loosen the four nuts on the bottom of the adjuster block.

• Page 59
  THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: •…

• Page 60: Pre-Ride Inspections

  PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer- enced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Drive Belt Condition Steering System Brake Fluid…

• Page 61: Before Starting The Engine

  PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death.

• Page 62: Hood Latches

  PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed.

• Page 63: Brake Lever Travel

  PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the 1/2″ (1.3 cm) handgrip than 1/2″ (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.

• Page 64: Parking Brake Lever Lock

  PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock Brake Parking Brake only when you want the snowmo- Lever Lever Lock bile to remain stationary; for exam- ple, when parked on an incline for a period of five minutes or less.

• Page 65: Track Inspection

  PRE-RIDE INSPECTIONS Before Starting the Engine n Track Inspection WARNING! Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle. WARNING! Use of traction products such as studs increases the possibility of track damage and/or failure.

• Page 66: Suspension Inspection

  PRE-RIDE INSPECTIONS Before Starting the Engine n Suspension Inspection Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the follow- ing items on a weekly basis or before any long trip.

• Page 67: Start The Engine And Check

  Start the Engine and Check Engine Stop Switch Check the auxiliary shut-off switch for proper operation. Push the 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. Lighting Check the headlight (high and low beam), taillight, and brake light.

• Page 68: Operation

  OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. •…

• Page 69: Engine Break-In

  Premix the first tank of fuel with one pint of Polaris injection oil for each five gal- lons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

• Page 70: Oil Injection System

  Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends the use of VES Gold Plus Synthetic 2- cycle oil for this engine. See page 116 for the part numbers of Polaris products. Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage.

• Page 71: Starting The Engine

  Starting the Engine 1. Turn the key to the ON position. NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 2.

• Page 72: Stopping The Snowmobile

  Engine Stop Switch Fuel For peak performance, Polaris recommends the use of 91 octane fuel or higher. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel.

• Page 73: Fuel Resistor

  Never use deicers or additives containing methanol. Polaris also recommends the use of Carbon Clean Plus. See page 116 for the part numbers of Polaris prod- ucts. If you use fuel with up to 10% ethanol (sometimes labeled oxy- genated) do not add deicers or additives that contain any form of alcohol.

• Page 74: Low Oil Indicator Light

  Always check the oil level when refu- eling. Add oil as needed. The Polaris oil cap on the oil bottle is vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.

• Page 75: Track Warm-Up

  Track Warm-Up WARNING A loose track or flying debris could cause serious injury or death. Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle dur- ing warm-up or when the track is free-hanging.

• Page 76
  OPERATION Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly. Pull the switch up to the RUN position to allow restarting. Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.

• Page 77: Throttle Lever

  The lever and cable must return to the idle position quickly and completely. 4. If 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. OPERATION…

• Page 78
  OPERATION Electronic Reverse (PERCt) WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the gearcase or trans- mission if shifting is attempted when the engine is operating above idle speed. •…

• Page 79: Daily Storage

  Daily Storage At the end of each ride, park the snowmobile on a level surface and sup- port it at the rear with an appropriate track stand. The track should be suspended approximately 4″ (10 cm) off the ground. Remove the key and cover the snowmobile. Towing For your safety, do not attempt to use a tow hitch until you’ve read the following warnings and understand the proper hitch functions.

• Page 80: Maintenance

  Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner’s manual. You are responsi- ble for ensuring that the specified maintenance is performed. Polaris recommends that you contact an authorized Polaris dealer to perform…

• Page 81
  If you’re not familiar with safe service or adjustment procedures and the use of tools, or if you don’t feel comfort- able performing these tasks yourself, contact an authorized Polaris dealer for service. NOTICE: Hot components can cause damage to plastic. Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection.

• Page 82: Item See Page

  The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer. Item Clutch Alignment Offset…

• Page 83: Throttle Safety Switch

  Periodic Maintenance Interval Table Item Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake Fluid Idle RPM Throttle Lever Oil Pump Lever (synchronize) Throttle Cable Throttle Position Sensor Fuel Lines Fuel Filter Oil Filter Oil Lines Air Box Auxiliary Shut-Off…

• Page 84: Gearcase Oil Level

  MAINTENANCE Periodic Maintenance Interval Table Item Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Drive Shaft Bearing Skags (Wear Bars) Ski Saddle/Spindle Bolts Hood Straps Rear Wheel Idler Bolts and Nuts Camber Alignment Handlebar Centering Track Alignment Track Tension Front Limiter Strap Rail Slide Condition…

• Page 85: Gearcase Oil Level

  Clean the magnetic plug (2) every 500 miles (800 km) and whenever checking or changing lubricant. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 116 for the part numbers of Polaris products. NOTICE: Mixing brands or using non-recommended lubricants could result in excessive wear to chain, sprockets and bearings.

• Page 86: Throttle Cable

  MAINTENANCE Lubrication Throttle Cable Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the han- dlebars to the left and lubri- cate liberally as shown. Front Suspension The front suspension and steering components do not require lubrica- tion.

• Page 87: Rear Suspension

  MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 78 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

• Page 88: Spark Plugs

  MAINTENANCE Spark Plugs A new engine can cause temporary spark plug fouling due to the preser- vative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. NOTICE: Using non-recommended spark plugs can result in serious engine damage.

• Page 89
  Spark Plugs Normal Spark 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 for the engine and the service. Tip: The tip should not be white.

• Page 90: Intake Filters

  All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump. Fuel Filter/Fuel Lines See your Polaris dealer for replacement of the fuel filter every 1000 miles (or annually). Inspect the fuel lines regularly for signs of deterioration or damage.

• Page 91: Oil Filter

  4. Replace any damaged or missing components. 5. Clean the plastic surfaces next to the muffler with aerosol Carbure- tor and Throttle Body Cleaner. See page 116 for the part numbers of Polaris products. 6. Close the hood. MAINTENANCE…

• Page 92: Cooling System

  Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/ 40% water mixture. See page 116 for the part numbers of Polaris prod- ucts. Tip: Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.

• Page 93: Flushing The Cooling System

  To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh mix- ture of antifreeze and distilled water should be added. Have your Polaris dealer perform this service.

• Page 94: Bleeding The Cooling System

  MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly.

• Page 95: Brake Components

  Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 59. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate, approximately 1/16″ (1.5 mm). A kit is avail- able for replacing brake pads.

• Page 96: Brake Fluid

  1. Position the handlebars so the master cylinder is level. 2. Remove the master cylinder cover. 3. Add DOT 4 brake fluid only. Do not overfill. See page 116 for the part numbers of Polaris products. Sight Master Glass Cylinder…

• Page 97: Bleeding The Hydraulic Brake System

  Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever.

• Page 98: Removing Halogen Bulbs

  MAINTENANCE Lights Removing Halogen Bulbs Tip: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a resi- due, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel. 1.

• Page 99: Installing Halogen Bulbs

  Lights Installing Halogen Bulbs 1. Hold the bulb by its metal base and install it into the wire harness. 2. Insert the bulb into the housing. 3. Connect the spring to the housing. 4. Carefully flip the spring back into the housing, placing it around the wire harness.

• Page 100: Electrical System

  MAINTENANCE Electrical System RELAY LABEL START SOLENOID RELAY CHASSIS RELAY RELAY IGNITION RELAY FUEL PUMP RELAY FAN RELAY FUSE LABEL Ground side of start solenoid SPARE 20A None ACCESSORY Accessory plugs EMERGENCY SPARE 30A High beams Low beams Handwarmers CHASSIS Thumbwarmer Passenger handwarmers Work light…

• Page 101: Clutch System

  Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. NOTICE: The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated. Do not lubricate clutch bushings.

• Page 102
  MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist.

• Page 103: Drive Belt Adjustment

  MAINTENANCE Clutch System Drive Belt Adjustment Belt deflection should be adjusted without removing the clutch from the jackshaft. 1. Loosen the 7/16-inch jam nut on the belt width adjuster. 2. Using a 1/8-inch Allen wrench, adjust the threaded set screw as needed.

• Page 104: Drive Belt Removal

  MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. 1. Stop the engine after operating in a forward motion. 2.

• Page 105: Drive Belt Installation

  Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. Tip: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them from the left side of the vehicle.

• Page 106: Track Replacement

  Track Replacement When replacing the track, always install a track having the lug size rec- ommended for your model. See your Polaris dealer. NOTICE: Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel. Always install a track having the lug size recommended for your model.

• Page 107: Track Lubrication

  Track Lubrication 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 operating for extended periods on ice and other surfaces that have little or no snow for lubrication.

• Page 108: Track Tension

  MAINTENANCE Track Tension WARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track adjustment is critical for proper handling. Always maintain cor- rect tension and alignment.

• Page 109
  Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic rail slide. If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7. Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the track.

• Page 110: Track Alignment/Condition

  35 ft. lbs. (47.5 Nm). 5. Repeat steps 2 and 3 to verify proper alignment. Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indi- cate the minimum permissible slide thickness. Replace the rail…

• Page 111: Steering System

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

• Page 112: Ski Alignment

  WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.

• Page 113: Ski Skags

  Steering System n Ski Skags WARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.

• Page 114: Battery Removal

  MAINTENANCE Battery WARNING! Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1.

• Page 115: Battery Charging

  Check battery voltage each month during storage and recharge as needed to maintain a full charge. Tip: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge.

• Page 116
  MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 or greater.

• Page 117: Cleaning And Preservation

  Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 116 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts.

• Page 118: Battery Maintenance

  Lubricate all bushings and cables at the intervals outlined in the Periodic Maintenance Table beginning on page 78. Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion.

• Page 119: Electrical Connections

  MAINTENANCE Extended Storage 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 exhaust parts. Track and Suspension Moderate track tension should be maintained during summer storage. The snowmobile should be supported off the ground to allow the track to hang freely.

• Page 120: Polaris Products

  POLARIS PRODUCTS Part No. Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2877882 VES Gold Plus Synthetic 2-Cycle Engine Oil (qt.) 2877953 VES Gold Plus Synthetic 2-Cycle Engine Oil (2 qt.) 2877883 VES Gold Plus Synthetic 2-Cycle Engine Oil (gal.) 2877884 VES Gold Plus Synthetic 2-Cycle Engine Oil (2.5 gal.)

• Page 121: 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 oper- Drive clutch binding ating RPM during Driven clutch mal- acceleration or load function variations Harsh drive clutch Drive belt worn or engagement…

• Page 122
  TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch system components Bearing failure/ gearcase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain worn, sprocket teeth bro- Poor low RPM Worn drive belt performance Excessive belt/…
• Page 123
  Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails Faulty ignition to start No fuel to engine Poor engine com- pression Engine lacks power Fouled or defective spark plug(s) Fuel filter (loss of high RPM power) Incorrect clutching Engine continually Faulty plug(s) backfires Fuel System…

• Page 124: Suspension Troubleshooting

  TROUBLESHOOTING Suspension Troubleshooting Problem Rear suspension bottoms too easily Rides too stiff in rear Too much weight transfer when climbing Too little weight transfer when climbing Front end pushes Steering is heavy Machine darts from side to side Solution • Set static sag (see page 50). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions.

• Page 125: Drive Belt Wear/Burn

  Drive Belt Wear/Burn Cause Driving at low Drive at higher RPM. Gear the machine down. Check belt deflection. Insufficient warm- Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from the snow.

• Page 126: Warranty

  Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you. When contacting us about parts, service, or warranty, always provide the following information: 1.

• Page 127
  2. Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. 3. Polaris warranty will aid in notifying the proper owner when a unit is recovered WARRANTY…

• Page 128: Limited Warranty

  WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty.

• Page 129: Engine Oil

  How to Obtain Warranty Service If your snowmobile requires warranty service, you must take it to a Polaris dealer autho- rized 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).

• Page 130
  In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty.
• Page 131
  • Failures caused due to improper adjustments. • Failure due to unauthorized service. • Failures due to lack of service as required in the owner’s manual or Polaris updates. This includes off-season storage as listed in the owner’s manual. • Failure due to use of unauthorized parts or modifications.
• Page 132
  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.
• Page 133
  This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S.
• Page 134
  Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that you use only Pure Polaris parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle’s emission controls.

• Page 135: Maintenance Log

  Present this section of your manual to your dealer 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) 150 mi. (240 km) 500 mi.

• Page 136
  MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
• Page 137
  MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

• Page 138: Index

  INDEX Accessories ….55 Air Pollution ….6 Apparel .

• Page 139
  Passenger Warning ….25 Polaris Products ….116 Pre-Ride Checklist ….56 Pressure Cap Warning .
• Page 140
  INDEX Starting the Engine … . . 67 Starting the Engine, Restarting ..68 Steering Inspection … . 107 Steering System .

If the brothers equipped their first snowmobile with a lawnmower engine, low-power and unreliable, then for the next car they purchased a two-cylinder motorcycle engine that develops traction of
12 horsepower. This power, according to Edgar’s calculations, should have been enough to transport two riders at a speed of 30 miles per hour. The engine was mounted on a frame of thin-walled
pipes, which they themselves made using a primitive welding machine for homework.

It was impossible to create a real classic tracked vehicle in a garage, and the brothers decided to use the drive wheels from the garden tractor, a relatively small diameter, but wide enough so
that they would not fall into the snow. The calculation turned out to be correct, and after the pressure was reduced in the tires and the wheels settled, the movement on the virgin snow became
optimal — the design worked.

The new snowmobile, called the Polaris, was already more maneuverable, moreover, it literally “took off the bat”: the torquey motorcycle engine easily dispersed a light car. The Hitton brothers
decided to engage in the design and production of snowmobile equipment.

However, the inventors did not have enough money for the development of the project, and the brothers bought wholesale waste metal pipes of various profiles at a mechanical plant that worked
nearby. When enough material was collected, work began to boil in the garage under the house. To begin with, the Hitton brothers made three snowmobiles, which they immediately sold to local
residents, and purchased money for the next batch, which already consisted of five snow bikes, with the proceeds. The garage became crowded, I had to rent an additional room on the outskirts of
the city. So there was a workshop for the production of snowmobiles — «The Hitton Brothers and Company.»

• Polaris IQ 550/600 Shift is a brand of a sports snowmobile with a throttle engine, which allows to reach a speed of 100 km / h with stable control.
• Indy 600 SP — a machine with a powerful Liberty Cleafire engine with a capacity of 600 cc / cm. High engine performance is combined with low fuel consumption, thanks to the latter’s variable
  injection system.
• 600 RR — Race Replica snowmobile, model 2008, provides a fairly comfortable off-road driving. The machine is light, maneuverable, behaves stably at any speed.
• The 600 Rush is an innovative 2010 sports snowmobile. Almost all the latest proprietary developments are included in the design, the machine is characterized by an aggressive design and high
  engine throttle response.
• Rush 600 Pro-R is a popular 2011 model with an engine capacity of 125 liters. S., does not need an introduction. Sports contours are organically combined with a relatively low weight of 212
  kilograms.
• Switchback 600 Adventure — Polaris 600 SA snowmobile from the 2012 model line, features an elongated contour that allows you to place a 136-inch truck. The engine is two-stroke, well-proven
  in racing.
• Dragon 600/800 SP — sports snowmobile, 2009 release, created on the IQ platform. Available in two versions, with a forced motor and a calmer dynamics.
• 600/800 IQ — 2009 model, features a powerful motor that throws the car «straight off the bat.» Ideal for lovers of extreme driving.

• The Indy 800 SP is an excellent technical snowmobile with a lightweight and sturdy Pro-Ride chassis for easy handling at high speeds. Differs in engine efficiency.
• Rush 800 Pro-R — one of the first Polaris snowmobiles, smoothly enters turns at speeds above 80 km / h while maintaining a sense of comfort.
• The Switchback 800 Pro-R is equipped with a 136-inch track, high-performance Walker Evans shock absorbers that are installed on all Pro-index vehicles. Model 800 features a wide, comfortable
  seat.
• 600 Dragon FST — the snowmobile has a truly draconian character, super-dynamic, although obedient to control. It is irreplaceable in races and in any other sports competitions.

• The IQ 700 is a sporty snowmobile with aggressive looks thanks to its 142 liter engine. with. provides the owner with a high level of adrenaline throughout the trip.
• IQ Shift — a wonderful tool for breathtaking journeys on the snowy plain, the extreme nature of the snowmobile will not let you get bored.
• Turbo IQ Dragon is a car from the 2009 lineup. Ideal for outdoor activities, sports competitions and just dizzying trips. A snowmobile driven by a 140 horsepower engine will always be ahead.
• Turbo IQ — a fast car for snowy spaces. Sporting performance is impeccable, the car runs smoothly and confidently in a given mode.

• Shift 550 136 is a universal machine for various activities in mountain conditions.
• 600 LX — comfortable and reliable mountain all-terrain vehicle. Equipped with an engine of 125 horsepower.
• 600 Pro-RMK — the snowmobile features a spring-hydraulic rear suspension with Walker Evans shock absorbers and other know-how.
• Shift 600 136 — a car designed for long trips, equipped with a powerful engine and a spacious fuel tank.
• Dragon 800 Switchback — the snowmobile of the increased comfort, differs in ease in management.