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1. Diagnostic Codes Component Condition SPN FMI ECU Memory Checksum CRC Error 628 13 Injector 1 MAG Port Injector Driver Circuit Open Grounded 651 5 Driver Circuit Short to B 3 Injector 2 PTO Port Injector Driver Circuit Open Grounded 652 5 Driver Circuit Short to B 3 Knock Sensor 1 Voltage Too Low 731 4 Ignition Coil Primary Driver 1 MAG Driver Circuit Open Grounded 1268 5 Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 Knock Level Cylinder 1 MAG Maximum Detonation 1352 0 Correction Limit Reached Knock Above Critical Level 16 Knock Level Cylinder 2 PTO Maximum Detonation 1353 0 Correction Limit Reached Knock Above Critical Level 16 Sensor Supply Voltage 1 TPS Voltage Too Low 3509 4 TMAP Sensor Power Sensor Supply Voltage 2 Ground Voltage Too Low 3510 4 Speed Sensor ECU Output Supply Voltage 2 Injec Voltage Too High 3598 3 tion Supply PWR Voltage Too Low 4 Throttle Release Signal Voltage Too High 520194 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 Driver Circuit Grounded 520215 5 Driver Circuit Short to B 3 Fuel Type Selected Voltage Too High 524007 3 Voltage Too Low 4 Signal Out Of Range 2 47 THE PERFECT FIT Suspension Adjustments Initial Spring Preload Setting Sag
2. ALTITUDE Drive Clutch Drive Clutch Driven Clutch Driven Chaincase Meters Shift Weight Sprin Sprin Helix Gearing Feet g pring pring Pitch Shaded cells indicate factory settings 0 600 10 64 Black Green 130 180 P2 Tab 58 42145 22 40 0 2000 1321585 7042083 7043873 72 Pitch 5137176 600 1200 10 62 Black Green 130 180 P2 Tab 58 42145 22 40 2000 4000 1321586 7042083 7043873 72 Pitch 5137176 1200 1800 10 60 Black Green 130 180 P2 Tab 58 42145 22 40 4000 6000 1321587 7042083 7043873 72 Pitch 5137176 1800 2400 10 58 Black Green 130 180 P2 Tab 58 42145 22 40 6000 8000 1321588 7042083 7043873 72 Pitch 5137176 2400 3000 10 56 Black Green 130 180 P2 Tab 835 45 20 41 8000 10000 1321684 7042083 7043873 72 Pitch 5137176 3000 3600 10 AL Black Green 130 180 P2 Tab 58 42145 20 41 10000 12000 1321531 7042083 7043873 E1376 72 Pitch 108 SPECIFICATIONS 800 SWITCHBACK ASSAULT Capacities and Dimensions Body Style PRO RIDE Rider Capacity 1 Coolant Capacity 5 qts 4 7 1 Chaincase Oil Capacity 9 oz 266 2 ml Fuel Tank Capacity 11 5 gal 43 5 1 Gearcase Oil Capacity N A Oil Capacity 3 8 qts 3 6 1 Height 48 inches 122 cm Length 126 inches 320 cm Designed Width 48 inches 122 cm Brake Type Hayes Cyclone Drive Clutch Center Distance 11 5 inches 29 cm Drive Belt P N 3211115 Clutch
3. 0 59 Engine Stop Switch 66 Environment Preservation 6 Exhaust System 87 F Fasteners Hood and Side Panel 57 Fluid Change CHAIMICAS Gg esaing odie sotssnecheaseracs 79 Coolant s eei bined a 85 Fluid Level Brake Fluid 89 Chaincase ecte bee ge cease 79 Coolant 5 66 donps dc eonoecaredgadonsldes 84 PUG os ibd adn see he tare earns eases 63 Puel 6 ae 81 F el Lines soo 5 a cnseccece ceace en iiss 81 Fuel Premix Initial Fill 60 Fuel Pump is scossi eee sess s 81 Fuel Recommendation 63 Fuel System Deicers 64 Fuel Type Selection 29 Fuel Warnings 00 63 H Handlebar Adjustments 51 Handlebar Angle 51 Headlight Adjustment 28 Headlight Lamp Replacement 91 Hood Fasteners ST Hood Side Panel Access 77 Hot Surface Warning 23 l Ice and Snow Build up 16 Ignition Lock System 31 39 44 Inadequate Snow Conditions 16 Indicator Lights 33 Information Display Area 36 Inspection Pre Ride 52 Instrument Cluster 32 47 Intake Filters 0 81 Intake Silencer 18 L Lights Headlight Replacement 91 Taillight Brake Light 91 Lubrication 78 80 Lubrication Rear Suspension 78 M Maintenance Inte
4. NOTE The system 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 3 After accepting the third digit view the display screen The new code and CODE SET will dis gt play if the system accepted your new code You will not see this display again NOTE Your new code is now set The system is NOT locked 4 Record your new security code in a safe place for future reference Record your new personal security code here TIP If you lose your personal security code see your dealer to have the code reset to 000 Then perform TASK 2 through TASK 4 to change the code to one of your own choosing 41 FEATURES Instrument Cluster Rider Information Center Security System Ignition Lock System Locking the System With Your Personal Security Code 1 Start the engine and lock the parking brake 2 Press and hold the MODE and SEL buttons SECURE for 3 seconds then release SECURE OFF 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 the first digit of your security cod
5. 49 TOWING syn Cana inia e 71 Track Alignment 100 IMS PECHOM 6 sic a ciie sods ae eases sees 97 Lubrication 97 TENSION s 05 4 hi guna odes es 98 99 Track Care for Storage 105 Track Inspection 57 Track Maintenance 97 100 Track Safety sensen eenia ee 10 Track Warm Up 0 62 Track Waning si o ise irni soens 23 Transporting the Snowmobile 104 Troubleshooting Drive Belt 117 Troubleshooting Engine 113 115 Troubleshooting Suspension 116 Tune UPerers ecis iret oan earners 104 V Vehicle Identification Numbers 7 WwW Windchill s ci csakcaxgecevedaes 20 PMS 419 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 9924273 Rev 01 Printed in USA POLARIS RRDA IONA TG ATT TT OVON OOOD DUON MNT
6. PMS 419 IMPORTANT NOTICE TO OWNER Modifications to this snowmobile are not recommended and may result in voided warranty coverage Please read the warranty section of this manual carefully 600 Switchback Assault 800 Switchback Assault Snowmobile Owner s Manual for Maintenance and Safety A WARNING 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 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polaris com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products e Snowmobiles e All terrain vehicles ATVs e Low emission vehicles LEVs e RANGER utility vehicles e RZR sport vehicles e VICTORY motorcycles e GEM vehicles We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS v
7. TIP Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the snowmobile and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel 4 Measure at the point where the weight is hanging 98 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 98 If the track needs adjustment 6 Loosen the rear idler shaft bolt 7 Loosen the locknuts Slack Measurement Adjusting Screw Lock Nut Shaft Vas l 16 inches 40 cm 10 Ibs 4 54 kg 8 Tighten or loosen the track adjusting screws to provide equal adjustment on both sides of the track 9 Repeat the measurement on the other side of the track TIP Check more frequently when the snowmobile is new 10 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 11 Check track alignment see page 100 and adjust as necessary 12 Tighten the locknuts 13 Tighten the idler shaft bolts 14 Tighten idler shaft bolts to 35 ft Ibs 47 5 Nm 99 MAINTENANCE Track Maintenance Track Alignment Periodically check that the track is centered and running evenly on the
8. Clutches 92 Cc Cc Cc Belt Tension z l l l l Clutch Sheaves 92 l l l l ENGINE COOLING Engine Mounts l l l l Recoil Rope l l l l Cylinder Head Bolts l l l Cylinder Base Nuts l l l Ignition Timing BTDC E l l l VES System Cc Cc Cc l Coolant Level 84 l l R l Coolant Hose l l l l Coolant Circulation l l l Coolant Leaks l l l l Spark Plugs 83 l l R l Exhaust Pipe 87 l l Exhaust Retaining 87 l l l l Springs Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 74 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page iso mi 500mi 1000mi 2000 mi Pre 240 km 800 km 1600 km 8200 km Season BRAKES Hose Routing l l l l Hose Condition l l l l Fluid Leaks l l l l Brake Pads 88 l l l l Brake Disc l l l l Parking Brakes 56 l l l l Brake System 55 88 l Brake Fluid 89 l FUEL MANAGEMENT Idle RPM l l l Throttle Lever 67 l l l l l Oil Pump Lever l l l synchronize Throttle Position Sensor l l l Fuel Lines 81 l l l l Fuel Filter 81 EVERY 2000 3200 or EVERY 2 YEARS Oil Filter 80 R R Oil Lines 80 l l l Air Box l l l l l ELECTRICAL Auxiliary Shut Off 58 l l l l l Switch Throttle Safety Switch 66 l l l l l Ignition Switch l l l l l Taillight 58 l l l l l Brakelight 58 l l l l l Hea
9. Release the key to the ON position when the engine starts 4 If not equipped with electric start grasp the starter handle and pull slowly until the recoil engages then pull abruptly to crank the engine TIP Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Damage may result 5 Ifthe engine does not start after several attempts slightly depress the throttle no more than 1 4 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 cold drive away is attempted the engine RPM may stumble slightly to protect the engine Restarting an Engine If the rider stops the engine by pushing the engine stop switch down restart the engine using the normal starting procedure If the engine fails to start using the normal procedure 1 Push the engine stop switch down to the OFF position 2 Turn the key to the OFF position 3 With both switches OFF squeeze and hold the throttle in the wide open position 4 Crank the engine several times to clear the engine Release the throttle 6 Restart the engine using the normal starting procedure m
10. 5 11 16 10 34 27 21 15 9 3 4 10 16 22 15 32 25 19 13 6 O 7 13 19 26 20 30 24 17 11 4 2 9 15 22 29 3 1 0 25 29 23 16 30 28 22 15 9 8 35 28 21 14 7 40 27 20 13 6 1 8 15 22 29 36 5 4 4 45 26 19 12 2 9 16 23 30 37 50 26 19 12 3 10 17 24 31 38 55 25 18 11 3 11 18 25 32 39 60 2517 10 3 4 11 19 26 33 40 Frostbite in gt gt 30 min 10 min 24 3 7 11 15 19 22 26 30 34 32 4 8 12 16 20 24 28 32 36 40 1 5 9 13 17 21 25 29 33 37 48 1 5 9 13 18 22 26 30 34 38 56 2 6 10 14 18 22 26 31 35 39 64 2 6 10 15 19 23 27 31 35 40 72 2 7 11 15 19 23 28 32 36 40 80 3 7 11 15 20 24 28 33 37 41 88 3 7 12 16 20 24 29 33 37 42 96 3 8 12 16 21 25 29 34 38 42 Frostbite in gt gt 30 min 10 min WINDCHILL CHART C Wind Actual Thermometer Reading C Speed 5 2 a 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 Km h Equivalent Temperature C
11. 59 OPERATION Break In Period Engine Break In Always follow these recommended break in procedures for new or rebuilt engines The first tank of fuel is considered the break in period for the engine Premix the first tank of fuel and fill the oil reservoir as outlined below Oil added to the fuel and oil injection systems will provide the necessary engine lubrication Oil Recommendations First Tank of Fuel POLARIS VES 2 Cycle Oil After Break in POLARIS VES 2 Cycle Oil See page 112 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 Oils may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All POLARIS oils are compatible with each other Initial Fuel Premix Always premix fuel in 5 gallon 19 liter increments in a separate fuel container Never add oil directly to the fuel tank Fuel VES 2 Cycle Oil Ratio Each 5 gal 19 I 16 oz 473 ml 40 1 60 OPERATION Break In Period Engine Break In Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle openings and vehicle speeds to reduce friction on all close fitting machined par
12. Black Green 130 180 P2 Tab 832 45 20 2 6000 8000 1321588 7042083 7043873 5137178 SANT 2400 3000 10 56 Black Green 130 180 P2 Tab 5842145 20 12 8000 10000 1321684 7042083 7043873 5137176 EA 3000 3600 10 AL Black Green 130 180 P2 Tab 5842 45 20 42 10000 12000 1321531 7042083 7043873 5137176 AS Bitch 107 SPECIFICATIONS 600 SWITCHBACK ASSAULT 1 3 Clutching Non Electric Start rel oie Drive Clutch Drive Clutch Driven Clutch Driven Conner Feet Shift Weight Spring Spring Helix Pitch Shaded cells indicate factory settings 0 600 10 64 120 310 Black 130 180 P2 Tab 58 42145 22 40 0 2000 1321585 7043681 7043873 5137176 72 Pitch 600 1200 10 62 120 310 Black 130 180 P2 Tab 5948145 22 40 2000 4000 1321586 7043681 7043873 5137176 72 Pitch 1200 1800 10 60 120 310 Black 130 180 P2 Tab 58 42145 22 40 4000 6000 1321587 7043681 7043873 5137176 72 Pitch 1800 2400 10 58 120 310 Black 130 180 P2 Tab 5941 45 22 40 6000 8000 1321588 7043681 7043873 5137176 72 Pitch 2400 3000 10 56 120 310 Black 130 180 P2 Tab 58 42145 20 41 8000 10000 1321684 7043681 7043873 oe 72 Pitch 3000 3600 10 AL 120 310 Black 130 180 P2 Tab 58 42145 20 41 10000 12000 1321531 7043681 7043873 5137176 72 Pitch Clutching Electric Start
13. Check Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never engage the starter when the engine is running Never start the engine without checking all vehicle components to be sure of proper operation See Before Starting the Engine beginning on page 54 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 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 operating Mirrors if equipped Adjust the mirrors so they can be used to their full advantage Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile 58 OPERATION Starting the Engine 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 1 Turn the key to the ON position 2 Pull the engine stop switch up to the RUN position 3 If equipped with electric start turn the key to START to crank the engine
14. INGOX 266455 nanea es a 130 INTRODUCTION Important Notes for Owners and Drivers After reading this manual store it in the snowmobile for convenient reference It should remain with the snowmobile when the snowmobile is sold Some of the illustrations and photos used in this manual are general representations Your model may differ Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile 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 Make sure they know how to drive and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses sponsored by local or state organizations INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education campaign We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment including wildlife and vegetation Snowmobile clubs and other organiz
15. OFF displays if F ra the system unlocks Re enter your code if BAD CODE displays bid NOTE The system is now unlocked COJE 43 FEATURES Instrument Cluster Rider Information Center Security System Ignition Lock System Changing to a New Security Code Any time you wish to change your current security code to a new code perform TASK 2 through TASK 4 of the First Time Use of Your Security System procedure beginning on page 40 Instead of using the factory default code 000 in TASK 2 and TASK 3 use your current security code Security 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 Chart Action Result Start engine Lock Displays ENTER CODE to lock the system parking brake Press and hold both MODE SELECT SEL Press SELECT SEL Advances a digit on the ENTER CODE screen Press MODE Accepts a digit and displays the next digit position if any remain on the ENTER CODE screen or Opens ENTER CODE screen if MODE is pressed immediately after locking and unlocking the system to change your security code 44 FEATURES Instrument Cluster Rider Information Center Diagnostic Display Mode The diagnostic display mode is for informational purposes only Please see your POLARIS dealer for all major repairs The diagn
16. OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 120 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law Promotional Warranties Promotional warranties are sometimes offered by POLARIS These warranties can be but are not limited to e Two year extended engine coverage e Two year powertrain coverage Extended service contract If you selected any type of extended warranty coverage as part of a POLARIS retail program please contact any authorized POLARIS dealer for additional information How to Obtain Warranty Service If your snowmobile requires warranty service you must take it
17. Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol non ethanol fuel Verify correct fuel resistor for fuel type resistor installed in tank Low fuel no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel filter or tank pick up sock See your POLARIS dealer for service Alcohol based fuel additive used with Do not add deicers or additives that Ethanol fuel contain any form of alcohol while using up to 10 Ethanol fuel Improper engine modifications Do not modify the engine Security System 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 prevent unauthorized use when leaving the snowmobile unattended A locked system will limit engine speed to 3000 RPM which prevents clutch engagement and the snowmobile will not move when throttle is applied If you wish to use this system see page 39 of the Instrument Cluster section for security system activation and operating instructions 31 FEATURES Instrument Cluster Rider Information Center Check Engine Indicator High Beam Indicator Over l A Temperature N af fod Z Park Brake Indicator LILLIE Ned Indicator i carl ICICI es AEO AO A A EEI omAGSESESiE Low Oil Reverse Indicator Indicator MODE SELECT Button Button The instrument cluster cont
18. Type P 85 Reverse Transmission Electronic Reverse Engine and Cooling Engine 4775 8044 OR8G Displacement 794 cc Cylinders 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 1800 200 Cooling Liquid Ignition Type CDI Ignition Timing 18 idle 1700 RPM w 120 F 49 C water temp Spark Plug Gap NGK BPR9ES 027 inches 0 7 mm Recommended Fuel Octane 91 recommended 87 minimum 109 SPECIFICATIONS 800 SWITCHBACK ASSAULT 2 0 Clutching Chart sara ie Drive Clutch Drive Clutch Driven Clutch Driven a Feet Shift Weight Spring Spring Helix Pitch Shaded cells indicate factory settings 0 600 10 66 120 310 Black LH BLUE BLACK 64 838 oA ANTO 0 2000 1321584 7043681 Team 7043064 ER 5135401 72 Bitch 600 1200 10 64 120 310 Black LH BLUE BLACK 6442 36 20 42 2000 4000 1321585 7043681 Team 7043064 Ep 6135401 72 Bitch 1200 1800 10 62 120 310 Black LH BLUE BLACK 64 42 36 20 42 4000 6000 1321586 7043681 Team 7043064 Ep 5135401 32 itch LHBLK PUR 64 42 36 20 42 1800 2400 10 60 120 310 Black 6000 8000 1321587 7043681 TEAM LW LW 21 41 INTL 7043363 ER 5135401 72 Pitch LHBLK PUR 64 42 36 20 42 2400 3000 10 60 140 33
19. U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be prepared be warm and be comfortable when riding Be aware of the weather forecast especially the windchill and dress accordingly See the chart on page 20 WARNING Avoid wearing loose clothing or long scarves which can become entangled in moving parts and cause serious injury Always wear an approved helmet and eye protection SAFETY Operator Safety Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Survival Preparation For your safety always ride in a group of other snowmobilers Always tell someon
20. Weight Spring Spring Helix Pitch Shaded cells indicate factory settings 0 600 10 64 120 310 Black 130 180 P2 Tab 58 42145 20 42 0 2000 1321585 7043681 7043873 6137176 72 Pitch 600 1200 10 62 120 310 Black 130 180 P2 Tab 58 42 45 20 42 2000 4000 1321586 7043681 7043873 72 Pitch 5137176 1200 1800 10 60 120 310 Black 130 180 P2 Tab 832 45 20 42 4000 6000 1321587 7043681 7043873 72 Pitch 5137176 1800 2400 10 58 120 310 Black 130 180 P2 Tab 58 48 45 20 42 6000 8000 1321588 7043681 7043873 72 Pitch 5137176 2400 3000 10 56 120 310 Black 130 180 P2 Tab 58142145 20 42 8000 10000 1321684 7043681 7043873 72 Pitch 5137176 3000 3600 10 AL 120 310 Black 130 180 P2 Tab 832 45 20 42 10000 12000 1321531 7043681 7043873 6137176 72 Pitch Clutching Electric Start ALTITUDE Chaincase Drive Clutch Drive Clutch Driven Clutch Driven Meters 7 Gearing Feet Shift Weight Spring Spring Helix Pitch Shaded cells indicate factory settings 0 600 10 64 Black Green 130 180 P2 Tab 58 42 45 20 42 4 P2N 21 41 INTL 0 2000 1321585 7042083 7043873 6137176 SAY 600 1200 10 62 Black Green 130 180 P2 Tab 82045 202 2000 4000 1321586 7042083 7043873 5137178 NT 1200 1800 10 60 Black Green 130 180 P2 Tab 5842145 20 82 4000 6000 1321587 7042083 7043873 5137176 SNT 1800 2400 10 58
21. belt cord line should be flush with or slightly above the outer circumference of the driven clutch sheaves The belt will seat itself in the driven clutch during the break in period Adjust the belt ride out after the break in period by readjusting belt deflection 2 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 If required separate the sheaves as outlined 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 over the outer clutch sheave Work the belt to the outer edge of the sheave 5 Rotate the L wrench to tighten the sheaves Remove the wrench and store in the tool kit 6 Reinstall the side panel 7 Break in the new belt See page 61 96 MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods can cause a rotating track to come off the snowmobile which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and support the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire length of each rod X Bend the track to check for break
22. crate or without proper dealer setup will void your warranty coverage Warranty Coverage and Exclusions Limitations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for purposes other than for which it was manufactured The warranty does not cover any damages that occur during trailer transit or as a result of unauthorized service or parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the snowmobile due to fire explosions or any other cause beyond POLARIS control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the snowmobile The exclusive remedy for breach of this warranty shall be at POLARIS exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES 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
23. fluid to the fill line as recommended 7 After bleeding is complete refill the reservoir to the proper level See page 89 8 Reinstall the gasket and cover 90 MAINTENANCE Lights When servicing a halogen lamp avoid touching the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp If fingers do touch a lamp clean it with denatured alcohol Headlight Lamp Replacement 1 2 3 4 5 6 Peel back the foam shield covering the headlight assembly Remove the wire harness connector from the back of the headlight Grasp the bulb housing and turn it counter clockwise to remove the bulb Apply dielectric grease to the socket and install the new bulb Rotate the bulb 1 4 turn clockwise to secure it Reinstall the connector to the back of the headlight Secure the foam shield Taillight Brake Light Replacement The taillight assembly is not serviceable If the light fails to operate properly replace the entire taillight assembly 91 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage wear or belt residue To maintain optimum performance clean with non oil based cleaners such as isopropyl alcohol WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern see your dealer immediately Do not operate the snowmobile until repairs have been made All clutch maintenance an
24. for damage 116 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear Burn Diagnosis Causes Solutions Driving at low RPM e Drive at higher RPMs Gear the machine down Check belt deflection Insufficient warm up 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 Towing at low RPM e Do not tow in deep snow Use fast aggressive throttle to engage clutch Riding with high RPM e Lower the gear ratio Reduce RPM Avoid riding in and slow speed 8000 high ambient temperatures Check for snow ingestion RPM 10 MPH 16 km h 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 Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the snowmobile completely onto the trailer Push and pull it to finish loading if necessary Clutch malfunction e Inspect clutch components See your dealer Slow easy clutch engagement e Use fast aggressive throttle to engage clutch 117 WARRANTY Service and Warranty Information
25. 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 Vehicle Model Number Tunnel VIN right side of tunnel Engine Serial Number on recoil housing Key Number 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 symbols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which 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 indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard SAFETY Operator Safety Follow the recommended maintenance program beginning on page 73 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage in
26. install a skag Rail Slide Wear For ease of inspection all 5 7 POLARIS rail slides have a wear limit indicator groove to indicate the Minimum minimum permissible slide Thickness thickness Replace the rail slides if they are worn to the top of the groove at any point along their length Failure to do so may result Replace when in permanent damage to worn to top of the track or rails groove 103 MAINTENANCE Fall Tune Up For maximum performance arrange for a fall service tune up with your POLARIS dealer His experienced and trained service technician will keep your snowmobile in peak operating condition Transporting the Snowmobile Whenever the snowmobile is transported 1 Be sure the fuel cap and oil cap are installed correctly 2 Tie the snowmobile to the transporting unit securely using suitable straps 3 Remove the ignition key to prevent loss 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 112 for the part numbers of POLARIS products Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood side panels chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be sure that corrosive salt and acids are removed from surfaces before begi
27. not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you contact an authorized 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 Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty ri
28. of warranty coverage Use of the recommended POLARIS products for lubrication and maintenance as directed by the Owner s manual is highly recommended Should a failure occur during the warranty period resulting from the use of non recommended products warranty coverage may be denied Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination The following items are excluded from warranty consideration if the failure was due to wear or not the direct result of a defect Skis Ski wear rods Tracks Slide rails Suspension components Finished and unfinished surfaces Brake components Carburetor Throttle body components Seat components Engine components Clutches and components Drive belts Steering components Hydraulic components Batteries Circuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of produ
29. 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 the digit 5 Press and release SEL to advance the third digit When 0 is displayed press and release MODE to accept the digit 6 After accepting the third digit view the display screen SECURE ON displays if the system locks NOTE The system is now locked SELUrE 7 You must now unlock the system Proceed imme diately to TASK 3 40 FEATURES Instrument Cluster Rider Information Center Security System Ignition Lock System First Time Use of Your Security System TASK 3 Unlock the System 1 When the engine is running the display will alternate between SECURE ON and ENTER CODE Wait until ENTER CODE SEN E displays then press and release SEL to cam advance the digit When 0 is displayed mdi Hea and release MODE to accept the igit 2 Press and release SEL to advance the second digit When 0 is displayed press and release MODE to accept the digit 3 Press and release SEL to advance the third digit When 0 is displayed press and release MODE to accept the digit 4 After accepting the third digit view the display screen SECURE OFF displays if the system unlocks SELU E OFF
30. spindles not to the ski loops to prevent damage to the steering components Remove the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary NOTICE Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 71 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain replace or repair the emission control devices or systems on your snowmobile Emission Control Label Your snowmobile is equipped at the time of sale with an emission control information ECI label and a factory installed emissions information hangtag These items are required by U S Environmental Protection Agency regulations The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover The ECI label should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specif
31. than the backing plate approximately 1 16 inch or 1 5 mm Brake Components 2 3 4 1 Brake Disc 2 Brake Caliper 3 Anti rattle springs come 1 with brake pad kit 4 Brake Pad Material Replace when thickness is less than 1 16 inch 1 5 mm Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops bring the snowmobile to an authorized POLARIS dealer for inspection and adjustment 88 MAINTENANCE Brakes Brake Fluid The brake fluid level can be seen through a plastic sight glass in the brake reservoir If the fluid is sufficient the sight glass will be black If the sight glass is any color other than black add brake fluid Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid See page 112 for the part numbers of POLARIS products WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it 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 diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function NOTICE Brake fluid
32. the country of the selling dealer 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 Warranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If You Move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS Industries in order to register your vehicle in your new country You should warranty register your vehicle at a local POLARIS dealer in your
33. will damage labels paint and some plastics Always wipe up spills immediately 89 MAINTENANCE 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 During the bleeding procedure keep the brake handle as level as possible The reservoir must be in this position to minimize the possibility of air entering the system through the 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 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 valve and release the brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles WARNING Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock resulting in serious injury or death Always add brake
34. 0 8000 10000 1321587 7043342 TEAM LW LW 20 42 INTL 7043363 ER 5135401 72 Pitch LHBLK PUR 64 42 36 20 42 3000 3600 10 58 140 330 10000 12000 1321588 7043342 TEAMON LW 20 42 INTL 7043363 ER 5135401 72 Pitch 110 SPECIFICATIONS 800 SWITCHBACK ASSAULT 1 3 Clutching Chart gr ea Drive Clutch Drive Clutch Driven Clutch Driven ee Feet Shift Weight Spring Spring Helix Pitch Shaded cells indicate factory settings 0 600 10 66 120 310 Black LH BLUE BLACK 64 12 36 23 39 0 2000 1321584 7043681 Team 7043064 Ep 5195401 72 Pitch 600 1200 10 64 120 310 Black LH BLUE BLACK 84 42 36 23 39 2000 4000 1321585 7043681 Team 7043064 p 135401 72 Pitch 1200 1800 10 62 120 310 Black LH BLUE BLACK 6442 36 23 39 4000 6000 1321586 7043681 Team 7043064 Ep s1g5401 72 Pitch LHBLK PUR 64 42 36 1800 2400 10 60 120 310 Black 23 39 TEAM LW LW 6000 8000 1321587 7043681 Goasses ER stas4o1 72 Pitch LHBLK PUR 64 42 36 2400 3000 10 60 140 330 21 41 TEAM LW LW 8000 10000 1321587 7043342 Goasses ER stas4o1 72 Pitch LHBLK PUR 64 42 36 3000 3600 10 58 140 330 21 41 TEAM LW LW 10000 12000 1321588 7043342 7043363 ER sig5401 72 Pitch 111 POLARIS PRODUCTS Part No Description Engine Lubricants 2870791 Fogging Oil 12 oz Aerosol 2877882 VES 2 Cyc
35. 16 inch jam nut on the belt width adjuster 2 Using a 1 8 inch Allen wrench turn the set screw inward clockwise to increase the distance between the sheaves or outward counter clockwise to decrease the distance 3 Tighten the jam nut 94 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 Rotate the driven clutch counter clockwise 1 4 turn by hand to ensure forward engagement before attempting to remove the belt 1 Stop the engine 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 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 belt If the wrench does not turn readily rotate the driven clutch counter clockwise an additional 1 4 turn by hand and try again 8 Firmly grasp the belt midway between the clutches and pull upward and rearward to remove it 95 MAINTENANCE Clutch System Drive Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack The
36. ARIS 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 controlled by the recovery system The recovery system components are e Coolant bottle overflow tank e Pressure cap e Connecting hoses Always maintain the coolant level at or slightly above the FULL COLD mark on the coolant bottle when the engine is cold 1 Stop the engine 2 Open the right side panel 3 View the coolant level in the coolant bottle 4 Add coolant as needed NOTICE Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recommended 84 MAINTENANCE Cooling System Engine Overheating The over temperature indicator on the instrument cluster will illuminate when the engine is overheating The indicator will flash when engine temperature reaches critical levels 100 Illuminated Indicator gt rear fool fod I Take action to cool the engine cl oo I opoKGE e Drive in loose snow e View the coolant level Do not open the pressure cap while the engine is hot Add coolant if the level is low e Stop the engine and allow it to cool down If you must continue to operate while the indicator light is illuminated drive slowly and stop the engine frequently to allow it to cool down Flashing Indic
37. Cam 5 2 Ja 4 7 10 13 16 19 22 8 3 o0 4 7 11 14 18 22 25 29 16 2 2 6 10 13 17 21 24 28 32 1 0 20 SAFETY Safety Labels and Locations Warning labels have been placed on the snowmobile for your protection Read and follow the instructions of the labels and other warnings on the snowmobile carefully If any of the labels depicted in this manual differ from the labels on your snowmobile always read and follow the instructions of the labels on the snowmobile If any label becomes illegible 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 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 clutches yourself See your dealer Pressure Cap Warning This warning label is found on the pressure cap of applicable liquid cooled models WARNING Do not open hot Test or replace when changing coolant Press down and turn to release cap 13 PSI 21 SAFETY Safety Labels and Locations Reverse No Passenger r Warning Warnin
38. Method To set up the rear suspension torsion spring preload measure the distance between the ground and rear bumper J This is measurement X i X Take this measurement with no rider and with the rear suspension at full l extension TIP The rear bumper may need to be lifted upward slightly to fully extend the suspension Next have the rider drop down hard on the seat and bounce up and down several times collapsing the rear suspension With the rider seated 7 measure the distance between the ground and the rear bumper at the exact location used for measurement J X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y from X Sag X Y Adjust sag by rotating the torsion spring preload cams located on the rear torque arm See illustration The ideal amount of sag for this rear suspension is five inches 12 7 cm X Y 5 in 12 7 cm If the rear suspension rides in less than four inches or more than six inches with the torsion spring preload cams at their maximum range of adjustment optional torsion springs softer or stiffer respectively may be required This is only an initial setup and final spring preload may vary based on rider preference and riding conditions 48 THE PERFECT FIT Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload rotate the three position cam using the engine spark plug tool Different rate torsio
39. Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty information contained in this manual Contact your POLARIS dealer for replacement parts service or warranty Your dealer receives frequent updates on changes modifications and tips on snowmobile maintenance which may supersede information contained in this manual Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following information 1 Serial number 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experienced 6 Length of time and conditions of operation 7 Previous correspondence Use the page 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 118 WARRANTY Service and Warranty Information POLARIS Anti Theft System The POLARIS anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines Administration 1 POLARIS snowmobile owner reports theft A In addition to notifying the proper law enforcement officials the owner must call POLARIS Customer Service B Owners must provide their name address telephone number and the model and serial number of stolen ma
40. TEM 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 70 OPERATION Daily Storage At the end of each ride park the snowmobile on a level surface and support it at the rear with an appropriate track stand The track should be suspended approximately 4 inches 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 WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the 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 and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski
41. age 4 Replace the track if any rod damage is found X Track Lubrication The slide rail 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 operating for extended periods on ice and other surfaces that have little or no snow for lubrication If excessive rail slide wear occurs due to poor snow conditions additional wheel kits are available See your dealer for more information Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty 97 MAINTENANCE Track Maintenance 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 Tension Track adjustment is critical for proper handling Always maintain correct tension and alignment TRACK TENSION DATA CHART Suspension Slack Measurement Weight Bagel ll nt PRO RIDE 3 8 1 2 inch 1 0 1 3 cm 10 Ibs 16 inches 40 cm RMK 4 54 kg ahead of rear idler shaft
42. ains indicator lights and the rider Mode Set Switch information center The information center can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the MODE SET switch on the left handlebar or console NOTICE Certain products will damage the lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Immediately clean off an any gasoline that splashes on the instrument cluster 32 FEATURES Instrument Cluster Indicators Check Engine Indicator This indicator appears if an EFI related fault occurs Do not operate the snowmobile if this warning appears Serious engine damage could result See your dealer See page 46 for diagnostic code definitions Over Temperature Indicator This indicator illuminates to alert the operator that the engine is overheating The operator should take action to cool the engine See page 85 If the indicator flashes continued operation could result in serious engine damage Stop the engine immediately Low Oil Indicator The low oil indicator light may flicker at times due to oil movement in the bottle but when the light comes on and remains on add the recommended oil before further operation See page 65 High Beam Indicator The high beam indicator illuminates when the lights are set to high beam Parking Brake Indicator This indicator illuminates when the parking brake is engaged It will also illuminate when the service br
43. ake is in use See page 56 Reverse Indicator This indicator flashes when the transmission is in reverse See page 69 33 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster The center displays vehicle speed engine speed odometer 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 an external DC power supply connector The information center is set to display standard units of measurement for distance and temperature To change to metric units see page 38 I tatata H A AGERE 34 FEATURES Instrument Cluster Rider Information Center 1 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 To change the display see page 36 2 Speed Display The speed display area displays either vehicle speed or engine speed To change the display see page 36 3 Odometer Engine Hour Display This area displays the odometer Trip A Trip B and engine hours To change the display see page 37 4 Battery Power This indicator illuminates when battery power is low 5 Playback Icon The playback function allows the rider to record and play back engine speed vehicle speed and throttl
44. arrow Excessive belt e SEE YOUR DEALER sheave clearance Drive belt turns over Wrong belt for appli e Replace the drive belt cation Clutch alignment out SEE YOUR DEALER Engine mount bro ken or loose Inspect and replace SEE YOUR DEALER Machine fails to move Clutch jammed e Check for twisted belt or broken spring SEE YOUR DEALER Track jammed e 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 113 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch SEE YOUR DEALER system components Bearing failure e SEE YOUR DEALER chaincase jackshaft or front drive shaft Drive belt surface e Inspect and replace as needed flat spots Drive chain loose e Inspect and adjust or replace Drive chain worn e SEE YOUR DEALER sprocket teeth bro ken Poor low RPM Worn drive belt e Inspect and replace as needed performance Excessive belt sheave clearance e SEE YOUR DEALER Sticky clutch e SEE YOUR DEALER Poor fuel quality e Use 87 91 octane fuel or higher Engine doesn t turn Seized engine e SEE YOUR DEALER Seizure is a result of poor lubrication inade quate f
45. arts beginning on page 73 Maintain the oil level at the top of the fill plug hole POLARIS recommends the use of POLARIS Synthetic Chaincase Lube See page 112 for the part numbers of POLARIS products Oil Level The fill plug is located on the right side of the snowmobile under the toe bar 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Using a funnel slowly add the recommended oil until the fluid begins to overflow 4 Wipe the fill area with a clean cloth 5 Reinstall the fill plug Torque to 6 10 ft Ibs 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 Torque to 6 10 ft Ibs 8 13 Nm 5 Remove the fill plug Clean off all metal shavings from the plug 6 Using a funnel slowly add the recommended oil until the fluid begins to overflow Fluid capacity is 9 oz 266 ml Wipe the fill area with a clean cloth Reinstall the fill plug Torque to 6 10 ft Ibs 8 13 Nm 79 MAINTENANCE Lubrication Oil Lines Inspect oil line condition every 1000 miles 1600 km Oil Filter The oil filter is located at the side of the oil tank Have your dealer change the oil fil
46. ation Center Diagnostic Display Code Definitions Open Load There is a break in the wires that lead to the item listed in the chart injector fuel pump etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internally Short to Battery The wire leading from the item listed in the chart 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 Too Low 4 Engine Temperature Sensor Voltage Too High 110 3 Voltage Too Low 4 Temperature Too High 16 Engine Overheat Shutdown 0 Temperature Above Normal Range 15 Alternator Power Supply Voltage Too High 167 3 Potential DC Chassis Voltage Voltage Too Low 4 Exhaust Temperature Sensor Voltage Too High 173 3 Voltage Too Low 4 46 Instrument Cluster FEATURES Rider Information Center Diagnostic Display Code Definitions
47. ations are working together to protect our environment Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that snowmobiles conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter machines we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly Air Pollution POLARIS engineers continuously investigate ways to reduce emission levels of two stroke engines We expect our efforts to lead to the reduction of potential air pollution In addition to our technological research we encourage government agencies manufacturers distributors dealers ecologists and other interested parties to work together to develop data on environmental topics INTRODUCTION Vehicle Identification Numbers Record your snowmobile s identification numbers and key number in the spaces provided Remove the spare key and store it
48. ator 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 Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine drain the system completely every two years and add a fresh mixture of antifreeze and distilled water This service must be performed when the engine is cold Ask your POLARIS dealer to check the coolant when he performs the fall tune up on your snowmobile 85 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 If the pressure cap needs replacement contact your dealer for the correct part NOTICE If coolant flow becomes restricted or plugged coolant loss air lock or engine damage may result 1 Position the vehicle so that the top of the tunnel is level Elevate the front of the vehicle slightly if necessary 2 Make sure the engine is cold before continuing 3 Remove the right side panel 4 Fill the coolant bottle with properly mixe
49. cations Operation Warning The operation warning label is also located on the console Operation Warning WARNING To avoid serious injury or death read and understand all warnings and the Owner s Manual before operation If manual is missing contact a POLARIS dealer for a replacement This vehicle is capable of high speeds Buried objects or uneven terrain can cause loss of control Reduce speed and use extreme caution when operating in unfamiliar terrain Excessive speed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes to avoid unexpected obstacles or to stop safely Never consume alcohol or drugs before or while operating this vehicle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements continued on next page 24 SAFETY Safety Labels and Locations Operation Warning 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 red
50. ch rotate the spark plug counter clockwise to remove 4 Reverse the procedure for spark plug installation Torque to specification 5 Reinstall the spark plug cap Spark Plug Condition Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service TIP The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetor throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil or use of non recommended injection oil 83 MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50 50 mixture of ethylene glycol and distilled water which will provide adequate freeze protection under most conditions If the vehicle will be stored or operated at extremely low temperatures greater protection may be required Please see your POLARIS dealer When adding or changing coolant POLARIS recommends using POLARIS Antifreeze 60 40 Premix POLARIS Antifreeze is already premixed and ready to use Do not dilute with water Never exceed a 60 antifreeze 40 water mixture See page 112 for POL
51. ch Warning 21 Clutch Drive System Storage 105 Clutching Chart 107 110 Cold Weather Drive Away 18 Controls and Linkage Storage 105 Coolant 64 5 5 gunn econ ects eh oes 84 Coolant Level cece eevee ss 84 Cooling System 84 86 Cooling System Bleeding 86 Cooling System Flushing 85 Customer Service 118 D DE gig tenes oie a oie agen as 30 31 Detonation Elimination Technology 30 31 Diagnostic Display Codes 46 47 Diagnostic Display Mode 45 Disabled Operators 12 Display Standard Metric 38 Drive Belt Adjustment 94 130 D Drive Belt Break In 61 Drive Belt Condition 93 Drive Belt Deflection 94 Drive Belt Installation 96 Drive Belt Removal 95 Drive Belt Safety 18 Drive Chain Tension 87 Driver Awareness 0 14 Driving Downhill 17 Driving in Hilly Terrain 17 Driving on Slippery Surfaces 16 Driving Responsibly 19 E Electrical Connections Storage 105 Emission Control Information 72 Emissions Limited Warranty 125 126 Engine Break In 60 61 Engine Overheating 85 Engine Protection for Storage 105 Engine Restarting 59 Engine Safety 0 04 10 Engine Starting
52. checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to service or make adjustments to your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfortable 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 73 MAINTENANCE Periodic Maintenance Interval Table 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 See Frequency Page 450 mi 500mi 1000mi 2000 mi Pre 240 km 800 km 1600 km 8200 km Season CLUTCH Clutch Alignment Offset 92 l l l without belt Drive Belt Condition 93 l l l l
53. chines 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 119 WARRANTY Limited Warranty POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 provides a ONE YEAR LIMITED WARRANTY on all components of the POLARIS snowmobile against defects in material or workmanship Warranty period will vary regionally This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty The warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a POLARIS dealer Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS Initial dealer preparation and setup of your snowmobile is very important in ensuring trouble free operation Purchasing a snowmobile in the
54. ct use Loss of vacation personal time 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 contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 122 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from POLARIS Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military personnel on assignment outside
55. d coolant to the maximum mark Do not install the pressure cap at this time 5 Remove the bleed screw from the water outlet manifold and or the thermostat housing Allow the coolant to bleed through the system until it runs out the bleed holes Reinstall the bleed screw into the manifold 6 Add coolant to the coolant bottle to the maximum mark 7 Reinstall the side panel Always ensure that the hood and side panels are securely in place before starting the engine 8 Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air 9 Stop the engine and check the coolant bottle level Add coolant as needed Reinstall the side panel 10 Carefully and briefly touch the top of the tunnel cooler under the seat If the system is bled properly the cooler will be warm to the touch If not repeat step 8 Lift the front of the snowmobile slightly to assist in the bleeding 11 Remove the side panel Reinstall the pressure cap Reinstall the side panel 12 Carefully lower the front end of the snowmobile 86 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles 3200 km Always allow the engine and exhaust system to cool completely before inspecting CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running 1 Open the s
56. d repairs must be performed by an authorized POLARIS dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty NOTICE The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum performance See your dealer for service and adjustments A special tool is required to check for proper alignment 92 MAINTENANCE Clutch System Drive Belt Condition Periodically check the condition and tension of the drive belt 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 See Drive Belt Troubleshooting on page 117 Always carry a spare drive belt Store the spare belt in the belt clip located under the left side of the hood For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile 93 MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge 1 on the belt 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
57. dlight 58 l l l l l 75 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 450 mi 500 mi 1000mi 2000 mi Pre 240 km 800 km 1600 km 8200 km Season CHASSIS Ski Toe Alignment oe l l l Suspension Mounting l l l l l Bolts Bolt Torques See your dealer every 1000 mi 1600 km for inspection Rear Suspension l l l l l Fasteners Steering Fasteners l l l l Cc Suspension Shock Oil R Cooling Fins and l l l l Shroud Skags Wear Bars 103 Ski Saddle Spindle Bolts Drive Chain Tension 87 Hood and Side Panel 77 Fasteners Rear Wheel Idler Bolts 99 l l l l l Idler Bolt Jam Nut 99 l l l l l Camber Alignment l l l Handlebar Centering Tether Switch and Strap 58 l l l l l l Track Alignment 100 l l l l l Track Tension 98 l l l l l Front Limiter Strap l l l l l Rail Slide Condition 103 l Chaincase Oil 79 l R l R l Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate Bolt Torque Inspection To maintain proper chassis performance see your POLARIS dealer for a bolt torque inspection every 1000 miles 1600 km Item Description Engine Mounting Bolts Remove drive clutch and resonator for access to all bolts Chaincase Mounting Bolts Two 2 TORX head bolts on forward
58. e e Control Linkages e Fuel Line Fittings e Purge Valves e Clamps e Vapor Hoses e Pressure Relief Valves e Liquid Vapor Separator e Control Valves e Carbon Canister e Control Solenoids e Canister Mounting Brackets e Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 125 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of POLARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may
59. e 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 following items on a weekly basis or before any long trip Item See Page Check suspension mounting bolts for tightness Check rear idler wheel bolts for tightness 99 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter strap condition Check rail slide condition 103 Check track tension 98 Check ski runner skag condition 103 Check ski spindle bolts for tightness Check tie rod end nuts for tightness 53 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 Never start the engine without checking all vehicle components to be sure of proper operation Read and Understand Your Owner s Manual 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 fu
60. e position sensor information for up to three minutes The playback icon flashes while recording See page 37 33 FEATURES Instrument Cluster Rider Information Center Speed Display Area The speed display area displays either vehicle speed or engine speed Vehicle speed is displayed in either miles per hour MPH or kilometers per hour km h Engine speed is displayed in revolutions per minute RPM 1 To change which item 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 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 To change the display press and release the MODE button or the MODE switch until the desired item is displayed 36 FEATURES Instrument Cluster Rider Information Center Odometer Engine Hour Display Area This area displays the odometer Trip A meter Trip B meter and engine hours meter The odometer displays the total distance traveled by the vehicle since manufacture Each trip meter records the distance traveled by the vehicle on a trip if the meter is reset before each trip The engine hour meter displays the total hours the engine has been in operation since manufacture To change the dis
61. e where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the conditions you may encounter Such equipment may include but is not limited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cellular telephone Always carry the owner s manual on your snowmobile For added protection purchase and carry the following items on your snowmobile as well e Spare Drive Belt e Winter Survival Kit e Extra Set of Spark Plugs e Trail Map e Tow Rope e First Aid Kit e Extra Oil e Tool Kit e Fuel Deicer 12 SAFETY Operator Safety Rider Capacity This snowmobile is designed for a single rider only Never carry a passenger on this snowmobile 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 operation 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 s
62. eaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you re unable to continue up a hill turn the snowmobile downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill side of the snowmobile pull the rear of the snowmobile around and point the front end and skis downhill Remount the snowmobile restart the engine release the parking brake and descend the hill carefully 17 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed Any servicing that requires operation without a belt must be performed by your dealer NOTICE Operation of the engine with the belt removed may result in injury or damage to the engine Intake Silencer Do not operate the engine with the intake silencer or filter removed NOTICE Damage to the engine may occur if the intake silencer or filter are removed Clutches Do not attempt to service the clutches All clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynamically balanced before installation Any tampering may disrupt this precision balancing and create an unstable condition Cold Weather Drive Away Whenever your sn
63. econds Traveling at night requires extra caution Check headlight and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your snowmobile to a stop in the distance illuminated by the headlight 13 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 Guy wires on utility poles are also difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your snowmobile will drown out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or highways Steep embankments may also hide your view Always leave yourself a way out QS Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Never travel on frozen bodies of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the snowmobile you and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over your entire route Snowmobile operators assume all risk a
64. ehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period POLARIS POLARIS PERC SWITCHBACK and ASSAULT are registered trademarks of POLARIS Industries Inc Copyright 2013 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 discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the original instructi
65. eis _ gt displayed press and release MODE to accept the digit TIP If the ENTER CODE screen exits due to inactivity repeat step 2 4 Continue to use SEL and MODE to select and accept the remaining two digits of the code 5 After accepting the third digit view the display screen SECURE ON displays if the gt _ es system locks Engine speed is now limited SECU E and the snowmobile cannot be driven a TIP When the engine is running the display will alternate between SECURE ON and ENTER CODE 6 If BAD CODE displays the screen will then return to the ENTER CODE screen Repeat _ gt steps 3 5 to re enter the security code bd 00 42 FEATURES Instrument Cluster Rider Information Center Security System Ignition Lock System Unlocking the System With Your Personal Security Code 1 When the engine is running the display will alternate between SECURE ON and ENTER CODE Wait until ENTER CODE displays then press and release SEL to advance the digit 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 4 C the correct password must be entered within 60 seconds or the engine will shut down Continue to use SEL and MODE to select and accept the remaining two digits of the code After accepting the third digit view the SECURE display screen SECURE
66. f Paans L D apee aioe 7 All L 5 hd ai atk o 2 an g 0 Dem be 4 Press and hold the SELECT button or SET switch until the desired fuel type is displayed in the center of the screen 29 FEATURES Detonation Elimination Technology DET The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active When excessive detonation is detected the check engine light will illuminate and you may notice decreased engine HO JOL fm for performance and RPM when the DET tl pef system is activated In most cases this Ta 57 is temporary and the operator does not C l j need to take any action The engine HY oA 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 down and restarted Check Engine Light Indicates Solid or Flickering Excessive detonation detected Steady Flashing Severe detonation detected RPM will be limited 30 FEATURES Detonation Elimination Technology DET The most likely causes of severe detonation are outlined in the troubleshooting table below DET Troubleshooting Cause of DET Activation
67. five minutes or less 1 Brake Lever 2 Parking Brake Lever Lock 3 Master Cylinder Reservoir Cover 4 Fluid Level Indicator Lock Engagement To engage the lock squeeze the brake lever tightly and push forward on the lock Hold the lock forward while releasing the brake lever TIP If the brake lever is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly The lock will return to the unlocked position WARNING If the parking brake lever lock is partially or entirely engaged while riding the brakes may overheat resulting in brake damage In extreme cases it could cause a fire which could result in serious injury or death Always ensure that the lever lock is completely disengaged before operating the snowmobile 56 PRE RIDE INSPECTIONS Before Starting the Engine Steering System 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 righ
68. g No Passenger Warning Snowmobiles designed for a single rider only have a NO PASSENGER warning label on the console WARNING This vehicle is designed for operator only NO PASSENGER Reverse Warning The reverse warning label is located 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 e 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 dash indicates reverse operation Push button again to return to forward 22 SAFETY Safety Labels and Locations Track Warning Hot Surface Track The track warning label is on the Warning Waring rear tunnel WARNING Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death Hot Surface Warning The hot surface warning is on the rear center of the tunnel WARNING Hot Surface Do Not Touch Burns may result Entire top of tunnel may be hot Install only accessories specifically approved for this model by POLARIS Do not place clothing bags or cargo on tunnel Do not cover this label 23 SAFETY Safety Labels and Lo
69. ghts and responsibilities please contact the POLARIS Warranty Department at 1 888 704 5290 126 MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km 127 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS KM 128 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 129 INDEX A ACCESSOFIES prenerien nanii hins 28 Air Pollution 33 sesieriicecieises 6 AyalancheS nr ieee eare ceems 15 B Belt Break In 61 Brake Lever Travel Inspection 55 Brakelight Replacement 91 Brakes 0200008 55 88 90 Brake Fluid 89 Components seiis 88 Inspection serico essrviregs 88 Lever Travel secie erenissss 88 System Bleeding 90 Break In Period 60 61 Cc Chaincase Oil 00 79 Cleaning Preservation Storage 104 Clutch Alignment Offset 92 Clutch Safety 000 18 Clutch System 92 96 Clut
70. headlight adjuster to the left to adjust the headlight beam upward Move the adjuster to the right to adjust the beam downward Accessories POLARIS offers a wide range of accessories for your snowmobile to help make each ride more enjoyable Use only POLARIS parts and accessories on your POLARIS snowmobile Use of unapproved parts and accessories may result in e Non compliance with government industry requirements e Voiding of warranty e Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems Exhaust systems are critical safety areas that must use approved POLARIS parts Please see your POLARIS dealer for service 28 Fuel Type Selection FEATURES Whenever using ethanol MTBE or other forms of oxygenated gasolines the fuel type designation setting must be changed to Eth in the gauge When using the recommended 91 non ethanol gasoline always select the 91 non setting Whenever in doubt of your fuel purchase use the Eth setting as a safeguard Use the following procedure to change the fuel type designation in the gauge Refer to the fuel type selection label located inside the left side panel 1 Start the engine 2 Lock the parking brake 3 Press and release the SELECT button or SET switch until FUEL is displayed in the lower section of the gauge j2 Pevaris D
71. hrough normal starting procedures 5 Ifthe 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 If an emergency exists and it s necessary to start the engine the throttle safety switch and engine stop switch may be disconnected from the wire harness When these switches are disconnected the ignition key switch must be used to shut off the engine DO NOT continue to operate the snowmobile with the throttle safety switch disconnected Return the snowmobile to an authorized POLARIS dealer for service as soon as possible 67 OPERATION Electronic Reverse PERC A WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed e Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle e Look behind the vehicle before and while backing e Avoid sharp turns e 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 transmission Is in reve
72. ications and adjustments for engine tune ups are located in the Service Manual which is available to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owner s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty and read the maintenance section of your owner s manual You are responsible for ensuring that the specified maintenance is performed POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 72 MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and perform service checks as outlined in this manual Record maintenance and service in the Maintenance Log beginning on page 127 The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles 240 km 500 miles 800 km and 1000 miles 1600 km These inspections should be performed by a qualified service technician For continued optimum performance and component life continue maintenance
73. ide panels and remove the hood See page 77 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 Drive Chain Tension Check drive chain tension weekly and before each long trip 1 Remove the side panels 2 Rotate the driven clutch counter clockwise 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 Jam Adjuster Nut Bolt 5 Tighten the jam nut while holding the adjuster bolt Torque to 21 ft Ibs 28 Nm 6 Reinstall the side panels 7 Release the brake lever lock 87 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile See page 55 Brake pads must be replaced when the brake pad material becomes thinner than the backing plate approximately 1 16 inch or 1 5 mm A kit is available for replacing brake pads See your dealer WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner
74. lays 2 Press and hold the SELECT button or SET switch until the units change 38 FEATURES Instrument Cluster Rider Information Center Security System Ignition Lock System This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer If you have this feature activated you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended A locked system will limit engine speed to 3000 RPM which prevents clutch engagement and the snowmobile will not move when throttle is applied If you wish to use this feature you must complete all four tasks on the following pages to have your system activated and to change the security code to one of your own choosing 39 FEATURES Instrument Cluster Rider Information Center Security System Ignition Lock System First Time Use of Your Security System Perform all tasks in the order shown if you wish to activate and use the optional security system TASK 1 Activate the security system See your authorized POLARIS dealer to have the optional security system feature activated in the electronic control unit ECU TASK 2 Lock the System the First Time 1 Start the engine and lock the parking brake 2 Press and hold the MODE and SEL buttons for 3 seconds then release SECURE OFF should be SECURE displayed If not repeat this step OFF 3 Wait until ENTER CODE displays then press and
75. le Engine Oil qt 95 I 2877953 VES 2 Cycle Engine Oil 2 qt 1 9 I 2877883 VES 2 Cycle Engine Oil gal 3 8 2877884 VES 2 Cycle Engine Oil 2 5 gal 9 5 Chaincase Lubricants 2873105 SCL Synthetic Chaincase Lubricant qt 95 1 2873106 SCL Synthetic Chaincase Lubricant gal 3 8 Grease Specialized Lubricants 2871312 Grease Gun Kit All Season 3 0z 89 ml 2871322 All Season Grease 3 0z 89 ml cartridge 2871423 All Season Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 I 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 1 Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT4 Brake Fluid 2872893 Engine Degreaser 2870505 Isopropyl Fuel De Icer 2872889 Brake and Clutch Cleaner 2872890 Carburetor and Throttle Body Cleaner Engine Lubricants 112 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 of spec Erratic engine oper Drive clutch binding SEE YOUR DEALER ating RPM during acceleration or load Driven clutch mal e SEE YOUR DEALER variations function Harsh drive clutch Drive belt worn or e Replace the drive belt engagement too n
76. lear of the track Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures NO STEP Stay Clear of Engine Never attempt adjustments with the engine running Turn off the ignition open the side panels or hood make the adjustment secure shields and guards secure the side panels and hood and then restart the engine to check its operation WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience and the features available on some snowmobiles 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 WARNING Improper riding position may reduce control and could result in serious injury or death Always ride in a position that allows for control of your vehicle 10 SAFETY Operator Safety Riding Apparel Helmet Wearing a helmet can prevent a severe head injury Whenever riding a POLARIS vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a
77. lure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up of the engine drive train and track 1 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 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions TIP It will take longer to warm up the track sufficiently during colder outdoor temperatures 4 Release the throttle apply the brakes shut off the engine and lower the snowmobile to the ground 5 Grasp the skis by their front loops and move them from side to side to loosen snow and ice Slide Rail and Track Cooling NOTICE Inadequate cooling and lubrication will lead to overheating of the slide rail and track resulting in premature wear and failure Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating on ice hard packed surfaces or roads 62 OPERATION Fuel AWARNING Gasoline is highly flammable and explosive under certain conditions e 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
78. 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 If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage 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 Slow down and use extra caution when operating 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 lubrication will lead to overheating of the slide rail and track causing premature wear damage and failure which can result in serious injury Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating for prolonged periods on ice hard packed surfaces or r
79. n springs are available if a firmer ride is desired Contact your dealer for Soft long end of cam to front more information The following information is provided only as a guideline to be used for initial suspension set up Your set up may vary hea i idi e we based on your desired riding style chor enc oncaniuipy Shock Compression Damping Compression damping can be adjusted at the front suspension and at the rear track shock Make adjustments in 2 click increments then test ride When adjusting the front suspension always am long end of cam up adjust both clickers equally To stop bottoming of the front or rear suspension stiffer ride rotate the clicker s clockwise two clicks as viewed from the top of the clicker then test ride Repeat the adjustment until bottoming stops and the desired ride quality is achieved For amore plush ride at the front or rear suspension rotate the clicker s counter clockwise two clicks then test ride Repeat the adjustment until the desired ride quality is Front Track achieved Shock Rear Track Shock 49 THE PERFECT FIT Suspension Adjustments Independent Front Suspension and Front Track Shock Spring Preload Factory settings combined with user adjustments to the rear track shock spring should be all that s necessary to provide the best riding experience for most riders The primary adjustment for overall vehicle balance is torsion spring preload Perform
80. nctioning properly Squeeze the throttle lever to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately Throttle Safety Switch Test the throttle safety switch system before the snowmobile is operated See page 66 54 PRE RIDE INSPECTIONS Before Starting the Engine 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 handgrip than 1 2 1 3 cm A smaller distance indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding information on page 90 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 89 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always have the brakes serviced at the first sign of sponginess 55 PRE RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary for example when parked on an incline for a period of
81. nd 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 Stretching the wires could damage the handwarmers Right control torque 27 in Ibs 3 05 Nm 10 Left control torque 24 in Ibs 2 7 Nm 10 3 Tighten the bolts 51 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 referenced pages Item See Page Drive Belt Condition 93 Steering System 57 Recoil Rope 57 Coolant Level 84 Chaincase Oil Level 79 Injection Oil Level 65 Parking Brake Lock Brake Lever Brake System 55 56 88 Auxiliary Shut Off Switch Engine Stop Switch 58 Ignition Switch 58 Headlight Taillight Brakelight 58 Suspension Mounting Bolts 53 Skags Wear Bars 103 Ski Saddle and Spindle Bolts 53 Hood and Side Panel Fasteners 77 Throttle Lever Safety Switch 66 67 Rear Wheel Idler Bolts 99 Tether Switch Strap if equipped 58 Track Alignment Condition 57 100 Rail Slide Condition 103 52 PRE RIDE INSPECTIONS Pre Ride Suspension Inspection Loos
82. new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and notices regarding your vehicle 123 WARRANTY How to Get Service 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 notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call POLARIS Customer Assistance see page 118 124 WARRANTY U S A EPA Emissions Limited Warranty 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 applicable U S Environme
83. nning 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 and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components 104 MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Maintenance Table beginning on page 74 Clutch and Drive System Remove the drive belt and store in a cool dry location Do not lubricate clutch components except the driven clutch shaft bushing as outlined in the Master Repair Manual See your dealer Engine Protection Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on precision engine parts during storage Whenever the snowmobile is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the container running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel Do not allow the snowmobile to run out of 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 exhaust
84. ntal Protection Agency emission regulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and continues for a period of 200 hours of engine operation 4000 kilometers 2485 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehicle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems e Air induction system e Ignition system e Fuel system e Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emissions e Aftertreatment devices e Sensors e Crankcase ventilation valves e Electronic control units The following parts are considered emission related components for evaporative emissions e Fuel Tank e Vacuum Control Diaphragms e Fuel Cap e Control Cables e Fuel Lin
85. o prevent damage resulting from fuel system icing Never use deicers or additives containing methanol POLARIS recommends the use of Carbon Clean See page 112 for the part numbers of POLARIS products If you use fuel with up to 10 ethanol sometimes labeled oxygenated do not add deicers or additives that contain any form of alcohol 64 OPERATION Oil Low Oil Level Always maintain the oil level between the add mark and the bottle neck Do not fill the bottle neck See page 60 for oil recommendations 1 Immediately stop the engine if the low oil indicator light comes on 2 Open the left side panel 3 View the oil level in the oil bottle 4 Add oil as needed before operating NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refueling Add oil as needed The oil bottle cap is vented to allow proper oil flow See your POLARIS dealer for recommended replacement parts 65 OPERATION Engine Stop Switch Push down on the engine stop switch X to ground N out the ignition and stop the engine quickly Pull the switch up to the ON position to allow restarting a 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 WARNING Opera
86. oads Operating in Deep Snow If the snowmobile becomes stuck in snow clear the running board area of snow then step down the snow in front of the snowmobile so that when the throttle is opened the snowmobile will be able to climb up and over the snow 16 SAFETY Operator Safety Driving Downhill When riding downhill shift your weight to the rear of the snowmobile and reduce your speed to a minimum Apply just enough throttle to keep the clutch engaged allowing the engine s compression to help slow the snowmobile and keep it from rolling freely downhill WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may result in brake failure Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system This condition may lead to a sudden loss of brakes and or fire and may result in serious injury or death Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and snowmobile rollover 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 r
87. on 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 misaligned see your dealer for alignment correction as camber adjustment may also be affected 102 MAINTENANCE Steering System 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 Check skags before each use of the snowmobile to ensure positive steering characteristics Skags must be replaced when worn to half their original diameter TIP Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement 1 Raise and support the front of the snowmobile so the skis are approximately 6 inches 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse the steps to
88. ons Printed in U S A 2014 600 SWITCHBACK ASSAULT 800 SWITCHBACK ASSAULT Owner s Manual P N 9924273 2 TABLE OF CONTENTS Introduction oicseu oes See ea cee ee eee 5 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner s manual Safely scdneectieeeeeeiesernnese lt saciens 8 This section describes safe vehicle operation and identifies warning labels and their locations Features icdccacdoavenaaa rak nataan kisa 26 This section identifies the locations of your snowmobile s controls and features The Perfect Fit naannanannnnnnnnnnnna 48 This section includes suspension set up information and explains how to make additional suspension adjustments for the perfect riding experience Pre Ride Inspections 0000005 52 This section explains procedures that must be performed before riding Operation ssnnnnnnnnnnnnnnnnnnnnn 59 This section explains proper engine break in operation of features and general operating procedures Maintenance aaananannnnnnnnnnsnnna 72 This section defines your role and your dealer s role in your snowmobile s regular maintenance Specifications 0s5e2 hese sdceasesanexs 106 POLARIS Products 2 5 112 Troubleshooting 0000e cece ee eens 113 Warranty sess ecaa e a ai ae a sent cheese was 118 Maintenance Log 5 127
89. ons A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization Change the spark plugs at the intervals outlined in the Periodic Maintenance Table beginning on page 73 Refer to the specifications section for the specific spark plug to be used in your snowmobile e Use recommended spark plugs with the proper gap e Use only resistor type spark plugs e Torque spark plugs to 18 22 ft lbs 24 30 Nm e 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 conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile Refer to the specifications section beginning on the page 106 82 MAINTENANCE Spark Plugs Spark Plug Inspection Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the left side panel 2 Remove the spark plug cap 3 Using the special wrench provided in the tool pou
90. ostic mode is accessible only when the check engine warning indicator is illuminated and a diagnostic code is active Do not stop the engine if you want to view the active code failure code Active codes cannot be retrieved if power is interrupted to the instrument cluster The codes will become inactive codes if power is interrupted Inactive codes are stored in the history of the unit Please see your POLARIS dealer to retrieve inactive codes Use the following procedure to view 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 mode will appear immediately following the engine hour display TIP When the diagnostic mode is displayed the check engine warning indicator will begin to flash 3 A set of two numbers will appear in the display e The 2 6 digit suspect parameter number SPN in the information display area indicates which component is generating the fault code e The 1 2 digit failure mode indicator FMI number in the odometer area indicates the fault mode such as open or short circuit 4 More than one fault may be active Press and hold the MODE button or MODE switch for two seconds to toggle to the next active code Repeat until all codes are retrieved 5 See page 46 for code definitions and failure descriptions 45 FEATURES Instrument Cluster Rider Inform
91. overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored e If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e 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 AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 63 OPERATION Fuel Recommendation 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 Do not use fuel containing more than 10 ethanol Never use E85 fuel in your snowmobile NOTICE Operating with obstructed fuel systems will result in serious engine damage Perform maintenance as recommended Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel Fuel System Deicers If you use non ethanol fuel sometimes labeled non oxygenated POLARIS recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline t
92. owmobile has been parked for a length of time especially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the snowmobile into motion but always operate within safety limits Maneuverability While much control and maneuverability is achieved through the steering system and skis maximum control is achieved by the shifting of your body weight Maneuverability will change for lighter operators or snowmobiles designed to carry a load 18 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently and even the most docile conditions may become dangerous if operators drive improperly If you re new to snowmobiling acquaint yourself with the snowmobile and with what it will and won t do under various conditions Even seasoned drivers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers e A snowmobile depends on the rider s body position for proper balance in executing turns traversing hills etc Always start on a smooth level area to begin building your operating experience e Before allowing someone else to use your snowmobile know the extent of their operating skills Check to see if they ve taken a snowmobile safety course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safety course Everyone can benefit f
93. 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 105 SPECIFICATIONS 600 SWITCHBACK ASSAULT Capacities and Dimensions Body Style PRO RIDE Rider Capacity 1 Coolant Capacity 5 qts 4 7 D Chaincase Oil Capacity 9 oz 43 5 1 Fuel Tank Capacity 11 5 gal 41 6 1 Gearcase Oil Capacity N A Oil Capacity 3 8 qts 3 6 D Height 48 inches 122 cm Length 126 inches 320 cm Designed Width 48 inches 122 cm Brake Type Hayes Cyclone 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 S4769 6044 OR6G Displacement 599 cc Cylinders 2 Bore x Stroke mm 77 25x64 Alternator Output 400 watt Throttle Body Mikuni Oil Injection VES Throttle Body Bore Size 46 mm Idle RPM 1700 200 Cooling Liquid Ignition Type CDI Ignition Timing 18 idle 1700 RPM w 120 F 49 C water temp Spark Plug Gap NGK BPR9ES 027 inches 0 7 mm Recommended Fuel Octane 91 recommended 87 minimum 106 SPECIFICATIONS 600 SWITCHBACK ASSAULT 2 0 Clutching Non Electric Start gr oa Drive Clutch Drive Clutch Driven Clutch Driven ee Feet Shift
94. play press and release the SELECT button or the SET switch until the desired item is displayed To reset a trip meter press and hold the SELECT button or the SET switch until the meter resets to zero Playback Function The playback function allows the rider to record and play back engine speed vehicle speed and throttle position sensor information for up to three minutes 1 To begin recording simultaneously press and hold the MODE and SELECT buttons on the instrument cluster for three seconds The playback indicator will flash while the instrument cluster is recording 2 To play back the recorded data stop the vehicle and wait for engine speed to drop below clutch engagement 3 Simultaneously press and release the MODE and SELECT buttons on the instrument cluster 4 Applying the throttle will clear the display and return the instrument cluster to normal operation 37 FEATURES Instrument Cluster Rider Information Center Standard Metric Display The odometer and temperature displays can be viewed in either standard or metric units of measurement Both displays change if units 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 disp
95. requires Poor fuel e Replace with fresh winter fuel more than normal pulls to start Not enough fuel get e SEE YOUR DEALER ting to engine Plugged fuel filter or e SEE YOUR DEALER 115 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension e Refer to the suspension adjustment and set up information bottoms too easily beginning on page 48 Revalve rear track shock see your dealer Rides too stiff in rear Refer to the suspension adjustment and set up information beginning on page 48 Check for binding suspension shafts and grease all pivot points Too much weight Refer to the suspension adjustment and set up information transfer when beginning on page 48 climbing Too little weight Refer to the suspension adjustment and set up information transfer when beginning on page 48 climbing Machine darts from side to side Check ski alignment see page 102 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Front end pushes e Check for worn skags Check for binding front suspension shafts and steering components grease all pivot points elevate front of snow mobile Increase IFS preload if equipped see page 50 Steering is heavy Make sure spindles and all steering components turn freely e Check ski alignment see page 102 e Check skags and skis
96. rom the course e Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions Your snowmobile is not intended for this kind of use e Be courteous to oncoming traffic by dimming your headlights and reducing your speed e When traveling in a group of snowmobiles don t tailgate follow too closely Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions Be aware of any snowmobile traffic around your vehicle Drive defensively to avoid accidents e Remove the key from the ignition when you leave the snowmobile unattended 19 SAFETY Operator Safety Windchill Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding WINDCHILL CHART F Wind Actual Thermometer Reading F Speed 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 MPH Equivalent Temperature F Calm 40 35 30 25 20 15 10 5 O 5 10 15 20 25 30 35 40 45 5 36 31 25 19 13 7 1
97. rse Never engage the starter when the engine is running 68 OPERATION Electronic Reverse PERC Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your vehicle is clear 3 Push the yellow reverse button on the left hand control for one second then release The engine will automatically reduce RPM and start a reverse rotation A flashing reverse light on the instrument panel will indicate that the transmission is in reverse 4 Apply the throttle slowly to make sure the transmission is in reverse 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 transmission is in reverse Never engage the starter when the engine is running 2 Push the yellow reverse button for one second and release The engine will slow and begin to rotate forward The light on the instrument panel will shut off 3 Apply the throttle slowly to make sure the transmission is in forward 69 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 66 for more information about the engine stop switch and throttle safety switch SYS
98. rval Table 74 76 Maintenance Program 73 Maintenance Recommendations 9 Maneuverability 18 Metric Standard Display 38 O Odometer Engine Hour Display 37 Oil Change Chaincase 79 Oil Filters ccaccsies eu wese ets 80 Oil Injection System 61 Oil Level Chaincase 79 Oil Level Injection 65 OGL TEINS Fico lrcrspd ors Pon eats eines 80 Oil Recommendations 60 Operating in Deep Snow 16 O Operation Warning 24 25 Operator Safety 8 20 Overheating Engine 85 P Parking Brake Lever Lock 56 Passenger Warmming 22 Playback Function 37 Polaris Products and Part Numbers 112 Pre Ride Checklist 52 Pre Ride Suspension Inspection 53 Pressure Cap Warning 21 R Rail Slide Wear 103 Recoil Rope Inspection 57 Registration Warranty 120 Reverse Operation 68 69 Reverse Warning 22 Rider Capacity 13 Rider Information Center 34 47 Riding Apparel 11 Riding Position 10 S Safety Labels i cies ccete lt ews 21 24 Safety Symbols 8 Sag Settings 48 Security System 31 39 44 Shock Compression Damping 49 Side Panel Access 77 Side Panel Fas
99. side of chaincase Four 4 rear chaincase nuts 76 MAINTENANCE Hood Side Panel The hood and side panels of the snowmobile protect the operator from moving parts Never operate a snowmobile with the hood or side panels open or removed Always ensure that the hood and side panels are securely in place before starting the engine To open a side panel rotate the two 1 4 turn fasteners at the upper edges of the side panel Release the side panel strap at F the lower edge of the panel To remove an open side panel 1 4 Turn Fasteners 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 77 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 74 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the life of the suspension Lubricate where indicated in the illustration below For more information about suspension lubrication and adjustments see your POLARIS dealer 78 MAINTENANCE Lubrication Chaincase Oil Check and change the chaincase oil at the intervals outlined in the maintenance ch
100. slide rails Misalignment will cause excessive wear to the track and slide rail 1 Safely support the rear of the snowmobile with the track off the ground 2 Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions 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 X are evenly spaced on each side If the track runs to the left loosen the idler shaft bolts then i dll mri tit loosen the left locknut and A lll tighten the left adjusting bolt If the track runs to the right loosen the idler shaft bolts then loosen the right locknut and tighten the right adjusting bolt 4 After adjustments are complete tighten the locknuts and torque idler shaft bolts to 35 ft Ibs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment 100 MAINTENANCE Steering System Steering Inspection Each week or before a long ride check all steering system fasteners and tighten if necessary 101 MAINTENANCE Steering System 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 1 Place the handlebars in a straight ahead position 2 With only vehicle weight compressing the suspensi
101. ssociated with ice conditions on frozen bodies of water When teaching inexperienced operators to ride set up a predetermined course for practice Make sure they know how to drive and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses 14 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain e Take an avalanche class e Travel with experienced people e Travel on designated trails e Make sure each person is equipped with a shovel probe and avalanche beacon You don t have to be snowmobiling on a slope for an avalanche to occur Be aware that all of the snow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in mountainous terrain Before riding in mountainous terrain call or log on to your local avalanche advisory to get current weather and snow stability information For more information about avalanche training and avalanche conditions contact local law enforcement in your area or visit the American and Canadian online avalanche centers at www avalanche org 15 SAFETY Operator Safety Ice and Snow Build up WARNING Ice and snow build up
102. t to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Track Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty WARNING Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle WARNING Use of traction products such as studs increases the possibility of track 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 cover icy trails and no snow conditions Hood and Side Panel Fasteners The hood and side panels of the snowmobile protect the operator from moving parts Never operate a snowmobile with the hood or side panels open or removed Always ensure that the hood and side panels are securely in place before starting the engine Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear is found see your POLARIS dealer for replacement 57 PRE RIDE INSPECTIONS Start the Engine and
103. teners 57 Signal Words 0 000 8 Ski Alignment 102 Ski Skags 0 000 103 Slide Rail and Track Cooling 62 Snow Conditions 16 Spark Plug Condition 83 Spark Plug Inspection 83 Spark Plug Recommendations 82 Spark Plugs 00 82 83 Speedi s eor saad date davai eat ee 13 Speed Display vs ccsigss sista esa 36 131 INDEX S Spring Preload 48 50 Standard Metric Display 38 Starting the Engine 59 Starting the Engine Restarting 59 Steering Inspection 101 Steering System 101 103 Steering System Inspection 57 Stopping Emergency 70 Storage Bag Under Seat 28 Storage Procedures 104 105 Storage Dally a cos sais edie oie aaes 71 Storage Tools ees 66 sensdiyess 28 Survival Preparation 12 Suspension Adjustments 48 50 Suspension Inspection Pre Ride 53 Suspension Lubrication Rear 78 Switches Engine Stop Switch 66 Mode Select Buttons 32 Mode Set Switch 32 Throttle Safety Switch 66 T Taillight Brakelight Replacement 91 Throttle Lever scecvsectacie seas s 67 Throttle Lever Inspection 54 Throttle Safety Switch 66 Throttle Safety Switch Inspection 54 132 T TOG Kits 224 3044044 eunn aneao 28 Torsion Spring Preload
104. ter and bleed the system annually or every 1000 miles 1600 xe km TIP The direction of the arrows indicates eee of flow through the ilter 80 MAINTENANCE 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 Fuel Pump 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 at the intervals outlined in the Periodic Maintenance Table beginning on page 74 Contaminated or poor quality 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 periods of storage Normal deterioration from weather and fuel compounds may occur Replace worn or damaged fuel lines promptly NOTICE Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly 81 MAINTENANCE Spark Plugs Spark Plug Recommendati
105. tervals A WARNING Driving a snowmobile requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger They will reduce your alertness and slow your reaction time Snowmobiles are capable of traveling at high speeds Use extra caution to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All POLARIS snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury The warranty on your entire machine is terminated if any equipment has been added or any modifications have been made to increase the speed or power of the snowmobile SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation Do not stand on the plastic flap 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 c
106. this adjustment first See page 49 After adjusting torsion spring preload and if desired additional adjustments can be made to the independent front suspension and front track shock preload When adjusting the front suspension be sure the springs on both sides of the vehicle are at the same adjustment Always perform shock spring preload adjustments with the weight of the vehicle removed from the shock and with the shock at full extension For a softer ride on rough washboard surfaces reduce front track shock FTS spring preload by 1 2 turns 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 the shock body Failure to do so could cause the retainer to fall off when the suspension is fully extended To improve corner stability increase front suspension IFS spring preload by 1 2 turns on both sides of the vehicle 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 50 THE PERFECT FIT Handlebar Adjustments Handlebar Angle 1 Loosen the four bolts on the top of the adjuster block If necessary pry the blocks apart with a screwdriver 2 Adjust the handlebar forward or rearward to the desired angle Be sure the handlebar brake lever a
107. ting the snowmobile with a faulty throttle 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 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration 4 Apply a slight amount of throttle A properly functioning switch must shut down the engine 66 OPERATION Throttle Lever WARNING An improperly functioning throttle lever may cause erratic snowmobile behavior and loss of control which could result in serious injury or death If the throttle lever does not work properly DO NOT start the engine If the engine stops abruptly when the throttle lever is released 1 Turn the ignition switch to OFF 2 Visually inspect the throttle cable and carburetor throttle body to determine what caused the safety switch to activate 3 Test the throttle lever by compressing and releasing it several times The lever and cable must return to the idle position quickly and completely 4 Ifthe throttle lever operates properly turn the ignition switch on and go t
108. 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 you may use any POLARIS Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at POLARIS if additional assistance is needed This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of POLARIS engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 121 WARRANTY Conditions and Exclusions 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 Failure to provide proof of required periodic maintenance upon request may result in denial
109. ts allowing them to break in slowly without damage NOTICE Use of any lubricants other than those recommended by POLARIS may cause serious engine damage We recommend the use of POLARIS lubricants for 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 the oil bottle when refueling See page 65 NOTICE Serious engine damage can occur without the proper lubrication Check the oil bottle level often during the first tank of fuel If the oil level doesn t go down contact your dealer immediately Drive Belt Break In The break in period for a new drive belt is 30 miles 48 km During this time vary the throttle position under 50 and limit full throttle use Always take time to warm up the belt and driveline prior to operating the snowmobile Free the track and skis from the ground before engaging throttle 61 OPERATION 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 during warm up or when the track is free hanging Use a stable rear support WARNING Use of traction products such as studs ice growsers etc will increase the possibility of track damage and or fai
110. uced Reduce speed and allow extra space to turn or stop To maintain vehicle control on ice or hard packed surfaces you should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for long periods Do not leave brake engaged for more than five minutes Before starting engine check throttle brake and steering for proper operation Make sure hood and side panels are latched Be seated and in position to control the vehicle Oil injection system Use unmixed fuel only Check oil level when refueling 25 FEATURES Nosepan Skis Front Bumper Hood Headlight Windshield accessory Handlebar AQ On Coll 26 8 Operator Seat 9 Taillight 10 Rear Bumper 11 Snow Flap 12 Suspension 13 Track 14 Side Panel 15 Side Panel Fasteners CON Od PON gt 11 12 0 FEATURES Fuel Filler Cap Electronic Reverse Button 12 11 10 Brake Lever Parking Brake Lock Instrument Cluster Ignition Switch Engine Stop Switch Throttle Control Recoil Starter Handle Handlebar Grip Warmer Switch Headlight Dimmer Switch MODE SET Switch 27 FEATURES Storage Bag Tool Kit Storage Bag A storage bag and tool kit is located under the left side panel between the oil bottle and console Adjustable Headlights Move the
111. uel supply broken parts or improper cooling Hydrostatic lock e Fuel may have entered the crankcase while the vehicle was standing or being transported SEE YOUR DEALER to correct the cause Drain plug s are located on the lower crankcase for emergency draining 114 Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails to start Faulty ignition TROUBLESHOOTING e Install new spark plug s If engine still fails to start check for spark If there s no spark SEE YOUR DEALER No fuel to engine Make sure the fuel valve is on Make sure tank contains fuel Ice may be in the fuel line filter or pump Add isopropyl alcohol to the fuel system SEE YOUR DEALER Poor engine com pression This indicates a major engine prob lem that must be repaired before operating SEE YOUR DEALER backfires Engine lacks power Fouled or defective Replace the plug s spark plug s Fuel filter loss of e SEE YOUR DEALER high RPM power Plugged fuel filter or e SEE YOUR DEALER tank pick up sock Incorrect clutching e SEE YOUR DEALER Engine continually Faulty plug s e Change plug s Fuel System Dirt or ice may be in the fuel system deicer should be added to non etha nol fuel at all times for assurance against fuel line icing tank pick up sock Incorrect throttle e SEE YOUR DEALER freeplay or faulty switch Engine

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