The Owner's Manual for this vehicle contains warnings, instructions and other information you must read and fully understand before safely riding or performing maintenance on this vehicle. Always follow the warnings and instructions in Owner's Manual.
Click the link above for the Table Of Contents, or download a full PDF of the Owner Manual in the Owner Support area of Polaris.com.
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2022 Owner’s Manual |
| RMK 144 Indy SP 129 Indy SP 137 |
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Copyright 2023 Polaris Industries 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 instructions.
Printed in U.S.A.
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. 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 vehicle, 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 can be performed by a factory certified Master Service Dealer (MSD) technician.
Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Your POLARIS dealership can perform all of your service needs during and after the warranty period.
For the most up-to-date owner’s manual visit
https://www.polaris.com/en-us/owners-manuals.
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.
DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor to moderate injury.
NOTICE provides key information by clarifying instructions.
IMPORTANT provides key reminders during disassembly, assembly, and inspection of components.
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.
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 at specific mileage intervals. This service can be performed by your authorized POLARIS dealer.
You and your authorized POLARIS 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.
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 organizations 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.
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.
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.
Record your snowmobile's identification numbers and key number in the spaces provided.
| 1 Certification Label |
| 2 Tunnel VIN |
| 3 Emission Certification Label |
| Vehicle Model Number: | |
| Tunnel VIN (right side of tunnel): | |
| Engine Serial Number (on recoil housing): | |
| Key Number: |
The engine serial number 1 is located on the identification label on the engine recoil cover.
The ignition keys are etched with an identification number. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank using the same identification number with one of your existing keys, so if both keys are lost, the ignition switch assembly must be replaced.
To report a safety defect to Transport Canada, you may either fill out an online defect complaint form at their website (English: http://www/tc/gc/ca/recalls, French: http://www.tc.gc.ca/rappels) or contact their Defect Investigations and Recalls Division by calling toll-free 1-800-333-0510 (Canada) or 819-994-3328 (Ottawa-Gatineau area / International).
Follow the recommended maintenance program beginning on POLARIS Recommended Maintenance Program of this manual to ensure that all critical components on the snowmobile are thoroughly inspected at specific mileage intervals. Your dealer can perform this service.
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.
Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Do not stand on the plastic flap.
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.
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.
Some POLARIS snowmobiles are designed for a single rider only, while some are designed for up to two riders. A safety label on the vehicle indicates whether the vehicle is designed for a single rider or for two riders.
Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See Windchill/Temperature Charts.
Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a 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 granted approval. The approval number and serial number will also be displayed on the label.
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.
For your safety, always ride in a group of other snowmobilers. Always tell someone 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:
Spare Drive Belt
Extra Set of Spark Plugs
Tow Rope
Extra Oil
Fuel Deicer
Winter Survival Kit
Trail Map
First Aid Kit
Tool Kit
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 seconds.
Traveling at night requires extra caution. Check headlight and taillight to ensure proper operation, and don’t over-drive your headlight beam. Always be able to bring your snowmobile to a stop in the distance illuminated by the headlight.
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 and bare roads limit the effectiveness of the steering system. Look ahead, behind, and to both sides before turning or crossing railroad tracks or highways. Steep embankments may also hide your view. Always leave yourself a way out.
Variances in snow depth and/or water currents 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 associated 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.
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.
Mountainous terrain operation, even for experienced riders, can present conditions and situations that could result in serious injury or death. Please review all of the information about riding in mountainous terrain on the following pages of this manual.
The avalanche information provided in this manual should be considered basic information and is not intended to replace your participation in an avalanche safety training course. After reviewing the avalanche information in this manual, be sure to participate in an avalanche safety training course before riding in mountainous terrain. The training course will provide more information as well as the opportunity to practice riding and using proper search and recovery techniques.
For more information, education, training courses, and links to additional resources, visit:
www.avalanche.org for North American riders.
www.avalanche.ca for Canadian riders.
www.lavinprognoser.se for Swedish riders.
www.avalanches.org for European riders.
In addition to carrying a spare belt, spark plugs and tools on each snowmobile, each person in your riding group should wear the recommended snowmobile riding apparel and carry (on their person) the following survival items when riding in mountainous terrain:
A digital avalanche beacon with new “fresh” alkaline batteries
An avalanche probe
A compact shovel and hand saw
A backpack (preferably an avalanche air bag backpack)
Emergency provisions, including the following items:
Small first aid kit
Extra pair of gloves
Extra dry socks
Tow rope, map, compass/GPS
Lighter or waterproof matches
Signal mirror and whistle
Bottled water
High calorie snack food
Compact emergency blanket
Following the safety gear and apparel recommendations will increase your chances of survival if you encounter an avalanche or become stranded in the backcountry, but even experienced and properly-equipped snowmobilers, hikers and skiers perish in avalanches or succumb to hypothermia. Using a beacon or probe for the first time during an avalanche recovery operation, or not knowing how to deploy your avalanche air bag backpack during a slide, should be considered UNACCEPTABLE to you and all members of your riding group. It’s critical that you and all members of your riding group know how to use the safety gear.
While you may know how to use your gear, you may have to rely on your riding group to find you in an avalanche. Make sure they know how to use their gear.
Dress in layers. Multiple layers of clothing provide the best barrier to cold and wind. Layers can be removed, but if you start out without enough layers, they cannot be added later. Avoid cotton materials, which will freeze if they get wet.
Wear highly visible gear.
Try on all gear and equipment to make sure it fits and doesn’t interfere with your riding capabilities. Place all survival aids in your backpack and wear the backpack at all times. Non-essential items can be stored on the snowmobile in an accessory bag.
Read and follow the manufacturer’s user and maintenance instructions for all gear. If you have questions about how your gear works, contact the manufacturer for more information.
Practice using your beacons, shovels and probes with your riding group in real-world conditions wearing all of your gear. Have someone hide an active “transmitting” beacon by throwing it (not walking it) into a snowbank and timing your group’s search for it.
Test deploying your gear. If you own an avalanche air bag backpack, check with the manufacturer’s test deployment guidelines and bottle weight replacement specifications. Most air bag backpack manufacturers recommend testing the pack once a year so you know it works and feel comfortable with the bag and deployment time.
Make sure your probe and shovel are in good condition and that you know how to assemble them.
Slopes steeper than 30º are more prone to avalanches, but any slope should be considered avalanche terrain, even small slopes with trees. Low-angle slopes are also avalanche terrain if they have steeper slopes above them.
Always look for the following warning signs of unstable snow. If you see or hear any of these signs, riding on or below any slope is dangerous and should be avoided:
Recent avalanches
A “whumpfing” sound under a snowpack
Cracks across the top of a snowpack
A recent heavy snowfall
Blowing snow
Rain
Rapid warming
Before riding, always tell a responsible person (i.e. at the lodge or gas station) where your group is going.
Never ride alone. Always ride in a small, manageable group. Riding in a large group makes it more difficult to track riders or find missing members.
Go “one at a time”. Only one snowmobile at a time should cross, ascend or highmark a slope. Other riders should watch from a safe location until the previous rider exits the slope.
Never park at the base of a slope or at the bottom of a gully or valley. When parking to take a break or watch other riders, park at the sides of the slope with the front of your snowmobile pointed away from the slope.
Make a riding plan based on the current avalanche and weather forecast. It is important to remember that overnight weather conditions may have created unsafe riding terrain that was considered safe the day before.
Follow the page links below to locate current avalanche reports and conditions for your area of operation.
www.avalanche.org for North American riders.
www.avalanche.ca for Canadian riders.
www.lavinprognoser.se for Swedish riders.
www.avalanches.org for European riders.
POLARIS recommends you and all members of your riding group participate in an avalanche safety course. Visit the education section of the Avalanche website for your region.
Avalanches are a matter of timing. A steep slope can be safe one day, but unsafe the next day due to changing weather and wind conditions.
Always review the user instructions provided with your safety equipment and follow the recommendations for maintenance, testing and use. Always test your safety equipment to ensure it works properly before riding in mountainous terrain.
Always store your survival gear in your backpack and wear the backpack. Do not store your survival gear on the snowmobile.
Always research current avalanche conditions in your area of operation before riding. Check with local law enforcement, resort or lodging personnel, gas station attendants and other riders to learn about current conditions and any advisories in the area.
Read and understand the avalanche danger scale. Pay attention to any danger level warnings issued for your area of operation.
Always remain alert while riding in mountainous terrain. Be aware of snowpack conditions above you as you ride. Avalanches can occur at any time regardless of current condition reports.
North American Public Avalanche Danger Scale
Avalanche danger is determined by the likelihood, size and distribution of avalanches.
| Danger Level | Travel Advice | Likelihood of Avalanches | Avalanche Size and Distribution | ||
|---|---|---|---|---|---|
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5 Extreme |
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Avoid all avalanche terrain. |
Natural and human-triggered avalanches certain. |
Large to very large avalanches in many areas. |
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4 High |
|
Very dangerous avalanche conditions. Travel in avalanche terrain not recommended. |
Natural avalanches likely; human-triggered avalanches very likely. |
Large avalanches in many areas; or very large avalanches in specific areas. |
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3 Considerable |
|
Dangerous avalanche conditions. Careful snowpack evaluation, cautious route-finding and conservative decision-making essential. |
Natural avalanches possible; human-triggered avalanches likely. |
Small avalanches in many areas; or large avalanches in specific areas; or very large avalanches in isolated areas. |
|
|
2 Moderate |
|
Heightened avalanche conditions on specific terrain features. Evaluate snow and terrain carefully; identify features of concern. |
Natural avalanches unlikely; human- triggered avalanches possible. |
Small avalanches in specific areas; or large avalanches in isolated areas. |
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1 Low |
|
Generally safe avalanche conditions. Watch for unstable snow on isolated terrain features. |
Natural and human-triggered avalanches unlikely. |
Small avalanches in isolated areas or extreme terrain. |
|
|
Safe backcountry travel requires training and experience. You control your own risk by choosing where, when and how you travel. |
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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.
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.
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.
Always be aware of surroundings and terrain when riding your snowmobile. Hazardous obstructions may be hidden beneath the snow. Reduce speed and use extra caution whenever riding off established trails. Striking a hidden obstacle could cause loss of control of your vehicle and lead to severe injury or death. Remain on established trails whenever possible to reduce exposure to hazards.
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.
Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you must cross the face of a slope, keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible roll-over.
Slow down when reaching the crest of a 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.
Do not operate the engine with the drive belt removed.
Any servicing that requires operation without a belt can be performed by your authorized POLARIS dealer.
Do not operate the engine with the intake silencer or filter removed.
Do not attempt to service the clutches.
All clutch service can be performed by your authorized POLARIS 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.
Whenever your snowmobile 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.
On 2-up machines, always operate with respect for a passenger.
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 based on rider weight and foot position on running boards.
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.
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.
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 from the course.
Don't “jump” your snowmobile over large drifts or similar terrain. Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground. The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions. Your snowmobile is not intended for this kind of use.
Be courteous to oncoming traffic by dimming your headlights and reducing your speed.
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.
Remove the key from the ignition when you leave the snowmobile unattended.
The following information is provided to help you determine when temperatures become dangerous for riding.
| Wind Speed in MPH | Actual Thermometer Reading (°F) | |||||||||||||||||
| 40 | 35 | 30 | 25 | 20 | 15 | 10 | 5 | 0 | -5 | -10 | -15 | -20 | -25 | -30 | -35 | -40 | -45 | |
| Equivalent Temperature (°F) | ||||||||||||||||||
| Calm | 40 | 35 | 30 | 25 | 20 | 15 | 10 | 5 | 0 | -5 | -10 | -15 | -20 | -25 | -30 | -35 | -40 | -45 |
| 5 | 36 | 31 | 25 | 19 | 13 | 7 | 1 | -5 | -11 | -16 | -22 | -28 | -34 | -40 | -46 | -52 | -57 | -63 |
| 10 | 34 | 27 | 21 | 15 | 9 | 3 | -4 | -10 | -16 | -22 | -28 | -35 | -41 | -47 | -53 | -59 | -66 | -72 |
| 15 | 32 | 25 | 19 | 13 | 6 | 0 | -7 | -13 | -19 | -26 | -32 | -39 | -45 | -51 | -58 | -64 | -71 | -77 |
| 20 | 30 | 24 | 17 | 11 | 4 | -2 | -9 | -15 | -22 | -29 | -35 | -42 | -48 | -55 | -61 | -68 | -74 | -81 |
| 25 | 29 | 23 | 16 | 9 | 3 | -4 | -11 | -17 | -24 | -31 | -37 | -44 | -51 | -58 | -64 | -71 | -78 | -84 |
| 30 | 28 | 22 | 15 | 8 | 1 | -5 | -12 | -19 | -26 | -33 | -39 | -46 | -53 | -60 | -67 | -73 | -80 | -87 |
| 35 | 28 | 21 | 14 | 7 | 0 | -7 | -14 | -21 | -27 | -34 | -41 | -48 | -55 | -62 | -69 | -76 | -82 | -89 |
| 40 | 27 | 20 | 13 | 6 | -1 | -8 | -15 | -22 | -29 | -36 | -43 | -50 | -57 | -64 | -71 | -78 | -84 | -91 |
| 45 | 26 | 19 | 12 | 5 | -2 | -9 | -16 | -23 | -30 | -37 | -44 | -51 | -58 | -65 | -72 | -79 | -86 | -93 |
| 50 | 26 | 19 | 12 | 4 | -3 | -10 | -17 | -24 | -31 | -38 | -45 | -52 | -60 | -67 | -74 | -81 | -88 | -95 |
| 55 | 25 | 18 | 11 | 4 | -3 | -11 | -18 | -25 | -32 | -39 | -46 | -54 | -61 | -68 | -75 | -82 | -89 | -97 |
| 60 | 25 | 17 | 10 | 3 | -4 | -11 | -19 | -26 | -33 | -40 | -48 | -55 | -62 | -69 | -76 | -84 | -91 | -98 |
| Frostbite in >> | 30 min. | 10 min. | 5 min. | |||||||||||||||
| Wind Speed in Km/h | Actual Thermometer Reading (°C) | |||||||||||||||||
| 5 | 2 | -1 | -4 | -7 | -10 | -13 | -16 | -19 | -22 | -25 | -28 | -31 | -34 | -37 | -40 | -43 | -46 | |
| Equivalent Temperature (°C) | ||||||||||||||||||
| Calm | 5 | 2 | -1 | -4 | -7 | -10 | -13 | -16 | -19 | -22 | -25 | -28 | -31 | -34 | -37 | -40 | -43 | -46 |
| 8 | 3 | 0 | -4 | -7 | -11 | -14 | -18 | -22 | -25 | -29 | -32 | -36 | -39 | -43 | -46 | -50 | -53 | -57 |
| 16 | 2 | -2 | -6 | -10 | -13 | -17 | -21 | -24 | -28 | -32 | -36 | -39 | -43 | -47 | -50 | -54 | -58 | -62 |
| 24 | 1 | -3 | -7 | -11 | -15 | -19 | -22 | -26 | -30 | -34 | -38 | -42 | -45 | -49 | -53 | -57 | -61 | -65 |
| 32 | 0 | -4 | -8 | -12 | -16 | -20 | -24 | -28 | -32 | -36 | -39 | -43 | -47 | -51 | -55 | -59 | -63 | -67 |
| 40 | -1 | -5 | -9 | -13 | -17 | -21 | -25 | -29 | -33 | -37 | -41 | -45 | -49 | -53 | -57 | -61 | -65 | -69 |
| 48 | -1 | -5 | -9 | -13 | -18 | -22 | -26 | -30 | -34 | -38 | -42 | -46 | -50 | -54 | -58 | -62 | -66 | -70 |
| 56 | -2 | -6 | -10 | -14 | -18 | -22 | -26 | -31 | -35 | -39 | -43 | -47 | -51 | -55 | -59 | -64 | -68 | -72 |
| 64 | -2 | -6 | -10 | -15 | -19 | -23 | -27 | -31 | -35 | -40 | -44 | -48 | -52 | -56 | -61 | -65 | -69 | -73 |
| 72 | -2 | -7 | -11 | -15 | -19 | -23 | -28 | -32 | -36 | -40 | -45 | -49 | -53 | -57 | -61 | -66 | -70 | -74 |
| 80 | -3 | -7 | -11 | -15 | -20 | -24 | -28 | -33 | -37 | -41 | -45 | -50 | -54 | -58 | -62 | -67 | -71 | -75 |
| 88 | -3 | -7 | -12 | -16 | -20 | -24 | -29 | -33 | -37 | -42 | -46 | -50 | -55 | -59 | -63 | -67 | -72 | -76 |
| 96 | -3 | -8 | -12 | -16 | -21 | -25 | -29 | -34 | -38 | -42 | -47 | -51 | -55 | -60 | -64 | -68 | -73 | -77 |
| Frostbite in >> | 30 min. | 10 min. | 5 min. | |||||||||||||||
Warning labels are placed on the snowmobile for your protection. Read and follow the instructions of the labels and 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.
The Fuel Type Warning label is located inside the left-hand side panel of your snowmobile and is only present on models equipped with a standard digital gauge.
CAUTION
The fuel designation gauge setting must be put in the “Eth” setting when using ethanol, MTBE, or other forms of oxygenated gasolines. When using the recommended 91 non-ethanol gasoline, put the gauge setting to “91-non”. Whenever in doubt of your fuel purchase use “Eth” setting as a safeguard.
Fuel Type Selection
Start the engine.
Press and hold the center 
button to enter the Options
Menu.
Press and release the MODE button until FUEL TYPE is displayed in the information display area.
Press and release the SET button to toggle through available options until the desired fuel type is displayed in the information display area.
To exit the Options Menu, press and release the MODE button until EXIT appears in the information display area.
Press and release the SET button to exit. The fuel type being displayed is the active fuel type.
Part number: 7185974.
The Oil Type Warning 3 is
located under the left-hand side panel on the oil bottle.
USE ONLY SYNTHETIC 2-CYCLE SNOWMOBILE OIL. FOR OPTIMUM
PERFORMANCE USE VES FULL SYNTHETIC.
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.
BELT REMOVAL – ALL UNITS
For electric reverse models, engine must be stopped in forward to allow clutch opening.
Install L-wrench from fender into the open threaded hole in the driven clutch.
Turn the L-wrench clockwise to open the sheaves and replace the belt.
Return the L-wrench to the fender.
SEE OWNER’S MANUAL FOR SHEAVE WIDTH ADJUSTMENT PROCEDURE.
Part number: 7181093.
The Tunnel Warning label is located on the rear of the tunnel.
WARNING
Hot Surface. Do Not Touch. Burn may result. Enter
top of tunnel may be hot. Install only accessories specifically approved
for this model by Polaris.
Part Number: 7184270.
WARNING
Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back can result in severe injury or death.
MAX. 25 lbs.
The Reverse Warning label 2 is located on either side of the operator seat.
WARNING
Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always:
Look behind before and while backing up.
Avoid sharp turns.
Shift to or from reverse only when stopped.
Apply throttle slowly.
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.
Part Numbers: 7176779 (English), 7176780 (French Canadian).
The No Passenger Warning label 1 is located on the left side panel below the recoil handle.
WARNING
This
vehicle is designed for operator only. “NO PASSENGER”
Part number: 7181012.
|
|
|
1 Brake Lever
2 Parking Brake Lock
3 Instrument Cluster
4 Ignition Switch
5 Engine Stop Switch
6 Throttle Control
7 Recoil Starter Handle
8 Handlebar Grip Warmer Switch
9 Thumb Warmer Switch
10 Electronic Reverse Button
11 Headlight Dimmer Switch
12 MODE/SET Switch
The ignition switch has three positions: OFF, RUN, and START.
1 OFF Vehicle / PIDD power off
2 RUN Vehicle / PIDD power on
3 START Activates starter motor
If the key remains in the RUN position after using the engine stop switch to stop the engine, the PIDD (POLARIS Interactive Digital Display) remains active. The PIDD screen will turn off after several minutes of inactivity, but if a battery is installed, the PIDD will continue to draw a small amount of current from the battery until the key is turned off. This feature is useful for accessing the PIDD without starting the engine, but turn the key off when the PIDD is not in use.
The PIDD is not dependent on a battery while the engine is running, but a battery (if installed) supplies a constant power source when the engine is turned off.
The battery trickle charge port is located inside the right footwell.
To ensure your battery maintains its level of charge, connect the battery charge port to a battery trickle charger. For more information, see the battery section of the Maintenance chapter.
Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher.
If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 or greater using the battery tender port 1.
If equipped, the 12-volt DC power receptacle is located on the hood next to the instrument cluster. The 12-volt power receptacle is protected by a 2 amp mini blade fuse located in the protective bag above the clutch cover. Use of the 12-volt DC power receptacle is recommended for connecting power-sensitive devices such as GPS units and cell phones.
Some rider accessories require the use of an RCA power adapter. If your model is not equipped with an RCA power plug on the handlebar cover, an accessory 12-volt RCA adapter or RCA power plug can be purchased from your POLARIS dealer.
The RCA adapter can be used if your model is equipped with the 12-volt DC power receptacle. Plug the adapter into the receptacle to convert it to a 12-volt RCA power outlet.
The RCA power plug (with cover) mounts to the handlebar cover and is plugged into the main vehicle wire harness. Installation instructions are provided with the accessory. This power point is powered by the load shed relay and is not fuse protected. POLARIS recommends using this power point for electric helmet shields.
The headlight can be adjusted for vertical aim using the following procedure.
In a well-ventilated area, position the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wall 1.
Place the rider or the approximate weight of the rider on the seat or tunnel floorboards.
Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
Start the engine. Move the headlight switch to high beam.
Observe the headlight aim on the wall. The most intense part of the headlight beam should be two inches (5 cm) 2 below the mark on the wall.
If adjustment is necessary, access the headlight adjuster knob through the left side panel. Turn the adjuster knob clockwise to lower the beam. Turn the adjuster counter-clockwise to raise the beam.
The belt removal L-wrench tool, spare belt, spark plug, and spark plug tool container are located behind the left engine compartment panel.
Spare belt and spark plugs are not provided with the snowmobile.
When properly engaged in the bracket, the L-wrench secures the fender to the console. To retrieve the L-wrench, rotate it counter-clockwise and slide it upward from the bracket. Return the L-wrench to the bracket and rotate it clockwise when it’s not in use.
The spark plug wrench secures the spare belt/spark plug tool container to the front bumper. Remove the container to add or access a spare spark plug or belt.
To insert a replacement drive belt into the spare drive belt container, do the following:
Rotate the spark plug wrench counter-clockwise to release it from the bracket.
Pull the wrench upward to remove it.
Tilt the container until the bracket detaches from the bumper tube.
Pull the container out of the compartment.
When placing a drive belt into the container, fold the belt so the loop at the rear of the container is positioned slightly higher than the front loop.
Slide the container into the engine compartment at an angle.
Position the container bracket onto the bumper tube and rotate it downward.
Reinstall the spark plug wrench into the bracket and through the hole in the bumper tube.
Rotate the spark plug wrench clockwise until it locks into place.
Some models are equipped with rail scratchers to help prevent overheating when riding on ice or hard-packed snow.
When DET senses and takes action to reduce detonation, the driver may notice a drop in engine RPM and/or reduced performance.
The ECU will illuminate the check engine LED and display “DETONATION” on the LCD screen whenever the DET system is active.
If the ECU determines the detonation cannot be controlled by normal means, and further operation may cause engine damage, the check engine LED will flash, the instrument clusters will display “DETONATION” and the ECU will either limit the maximum engine speed or turn off the engine.
If the ECU limits RPM, the limit will remain active until the driver stops and restarts the engine.
See the Troubleshooting chapter for possible causes of severe detonation.
|
DETONATION PROTECTION MODES |
|
|---|---|
|
Check Engine LED/Gauge Display |
Protection Mode |
|
LED illuminated / “DETONATION” displayed |
Slight drop in engine RPM/power |
|
LED flashing / “DETONATION” displayed |
Exhaust valves close to reduce engine RPM/power. Restart engine to reset. |
If the Engine Control Unit (ECU) senses a problem with the electronic oil pump control circuit, the engine management system will limit engine speed to approximately 4000 RPM and illuminate the check engine indicator light on the instrument cluster or PIDD.
If oil pump failure is detected, see your dealer or certified technician as soon as possible for servicing.
This engine feature causes the Engine Control Unit (ECU) to shut down the engine when engine temperature reaches a certain degree and no throttle lever input has been detected for several minutes. The table below depicts the shut down temperature and no throttle lever input duration for your model.
| Engine Model | Temperature | No Throttle Lever Input Duration |
|---|---|---|
| 600 | 122 f (50 c) | 11 minutes |
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 your model is equipped with the POLARIS Interactive Digital Display (PIDD), please see the PIDD Owner’s Manual provided with your snowmobile.
1 Check Engine
2 Engine Hot
3 Low Oil
4 Low Battery Voltage
5 Playback
6 Low Fuel
7 High Beam
8 Parking Brake
9 Reverse
10 Security
Certain products will damage the lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Immediately clean off any gasoline that splashes on the instrument cluster.
The instrument cluster contains indicator lights and the rider 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 11 on the Left Hand Control.
| Indicator | Condition |
|---|---|
|
This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning appears. Serious engine damage could result. Your dealer can assist. |
|
The over-temperature indicator will illuminate when the engine is overheating. Take action to cool the engine. The indicator will flash when engine temperature reaches critical levels. Stop the engine immediately. |
|
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. |
|
The low battery voltage indicator illuminates when the battery voltage is low. |
|
The playback indicator illuminates when the gauge is in playback mode. |
|
The low fuel indicator illuminates when fuel is low. |
|
The high beam indicator illuminates when the lights are set to high beam. |
|
The parking brake Indicator illuminates when the parking brake is engaged. It will also illuminate when the service brake is in use. |
|
The reverse indicator flashes when the transmission is in reverse. |
|
The security indicator illuminates when the security system is activated. |
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 a 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.
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.
2 Speed Display - The speed display area displays either vehicle speed or engine speed.
3 Fuel Gauge - Not available on all models. The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.
4 Odometer/Engine Hour Display - This area displays the odometer, Trip A, Trip B and engine hours.
This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature, maximum vehicle speed, and speed or RPM. To change the display, press and release the MODE button or the MODE switch until the desired item is displayed.
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).
To change which item displays, first make sure the information display area is set to display either engine speed or vehicle speed.
Press and release the center button.
The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.
If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. See your dealer.
This area displays the odometer, Trip 1 meter, Trip 2 meter, CLOCK, 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 CLOCK displays the time, and the engine hour meter displays the total hours the engine has been in operation since manufacture.
To change the display, press and release the SET button or SET switch until the desired item is displayed.
To reset a trip meter, press and hold the SET button or SET switch until the meter resets to zero.
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.
Press and hold the center 
button on the instrument cluster to enter the Options Menu.
Press and release the MODE button until PLAYBACK appears in the information display area.
Press and release the SET button.
RECORD will appear in the information display area.
To begin recording, Press and release the SET button.
The playback indicator will flash while recording is in progress. Recording is complete when the light stops flashing.
To play back the recorded data, stop the vehicle and wait for engine speed to drop below clutch engagement.
Press and hold the center button on the instrument cluster to enter the Options Menu.
Press and release the MODE button until PLAYBACK appears in the information display area.
Press and release the SET button twice.
PLAY will appear in the information display area.
Press and release the SET button to play the recorded data.
Once playback has concluded, REPLAY will appear in the information display area.
Press and release the SET button to REPLAY recorded data.
Press and release the MODE button to end playback and return to the Options Menu.
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
Press and hold the center button on the instrument cluster to enter the Options Menu.
Press and release the MODE button until engine temperature appears in the information display area.
Press and release the SET button or SET switch to change units.
Change Method 2
Press and release the SET button or SET switch until the odometer appears in the information display area.
Press and hold the SET button or SET switch until the units change.
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.
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
Press and hold the center button on the instrument cluster to enter the Options Menu.
Press and release the MODE button until SECURITY OFF appears in the information display area.
Press and release the SET button.
ENTER CODE will appear in the information display area.
Press and release the SET button to increase the 1st digit.
Press and hold the SET button to accept the 1st digit and advance to the 2nd digit.
Press and release the SET button to increase the 2nd digit.
Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit.
Press and hold the SET button to accept the 3rd digit and submit code.
If code is correct, SECURITY ON will appear in the information display area. The system is now locked. Proceed immediately to Task 3.
If code is incorrect, BAD CODE will appear in the information display area. Return to step 3 to re-enter code.
TASK 3: Unlock the System
While the engine is running, Press and release the SET button.
ENTER CO will appear in the information display area.
Press and release the SET button to increase the 1st digit.
Press and hold the SET button to accept the 1st digit and advance to the 2nd digit.
Press and release the SET button to increase the 2nd digit.
Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit.
Press and release the SET button to increase the 3rd digit.
Press and hold the SET button to accept the 3rd digit and submit code.
If code is correct, SECURITY OFF will appear in the information display area
If code is incorrect, BAD CODE will appear in the information display area. Return to step 1 to re-enter code.
You must now enter a new security code. Proceed immediately to TASK 4.
TASK 4: Enter Your New Security Code
Immediately after locking and unlocking the system, and while SECURE OFF is displayed, simultaneously press and hold the MODE and SET buttons.
SET NEW CODE will appear on the information display area.
Press and release the SET button to increase the 1st digit.
Press and hold the SET button to accept the 1st digit and advance to the 2nd digit.
Press and release the SET button to increase the 2nd digit.
Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit.
Press and release the SET button to increase the 3rd digit.
Press and hold the SET button to accept the 3rd digit.
CODE SET will appear in the information display area, and then the new code will blink three times in the information display area
Record your new security code in a safe place for future reference.
Record your new personal security code here: __________________
Start the engine.
Press and hold the center button on the instrument cluster to enter the Options Menu.
Press and release the MODE button until SECURITY OFF appears in the information display area.
Press and release the SET button.
ENTER CODE will appear in the information display area.
Press and release the SET button to increase the 1st digit.
Press and hold the SET button to accept the 1st digit and advance to the 2nd digit.
Press and release the SET button to increase the 2nd digit.
Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit.
Press and hold the SET button to accept the 3rd digit and submit code.
If code is correct, SECURITY ON will appear in the information display area. The system is now locked. Proceed immediately to Task 3.
If code is incorrect, BAD CODE will appear in the information display area. Return to step 3 to re-enter code.
While the engine is running, Press and release the SET button.
ENTER CODE will appear in the information display area.
Press and release the SET button to increase the 1st digit.
Press and hold the SET button to accept the 1st digit and advance to the 2nd digit.
Press and release the SET button to increase the 2nd digit.
Press and hold the SET button to accept the 2nd digit and advance to the 3rd digit.
Press and release the SET button to increase the 3rd digit.
Press and hold the SET button to accept the 3rd digit and submit code.
If code is correct, SECURITY OFF will appear in the information display area
If code is incorrect, BAD CODE will appear in the information display area. Return to step 1 to re-enter 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. Instead of using the factory default code “000” in TASK 2 and TASK 3, use your current security code.
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 |
|
Displays ENTER CODE (to lock the system) |
|
Press and release the SET button |
Advances a digit on the ENTER CODE screen |
|
Press and hold the SET button |
Accepts a digit and displays the next digit position (if any remain) on the ENTER CODE screen |
|
While SECURITY OFF is shown on the information display area, simultaneously Press and hold the MODE and SET button. |
Allows user to change security code. |
The diagnostic display mode is for
informational purposes only. Your authorized POLARIS dealer can perform
all major repairs.
The diagnostic 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 authorized POLARIS dealer can help retrieve inactive codes.
Use the following procedure to view active codes.
Do not stop the engine.
Press and hold the center button on the instrument cluster to enter the Options Menu.
Press and release the MODE button until DIAGCODE appears in the information display area. The Diagnostic display mode will appear in the Options Menu if there is an active trouble code.
When the diagnostic mode is displayed, the check engine warning indicator will begin to flash.
A set of two numbers will appear in the display.
The 2-6 digit suspect parameter number (SPN) in the information display area indicates which component is generating the fault code.
The 1-2 digit failure mode indicator (FMI) number in the odometer area indicates the fault mode, such as open or short circuit.
More than one fault may be active. Press and hold the SET button or SET switch for two seconds to toggle to the next active code. Repeat until all codes are retrieved.
See Diagnostic Trouble Codes for code definitions and failure descriptions.
The POLARIS Interactive Digital Display (PIDD) provides the rider with:
Speedometer
Tachometer
Odometer
2 Trip Meters
Fuel Level Indicator
Coolant Temperature
Battery Voltage
Fuel Type Selection
Vehicle Security
Gear Indicator
The PIDD also offers GPS mapping and Bluetooth® connectivity for compatible smartphones/devices. This feature will display text messages and missed phone calls on the display screen. The PIDD sub-menus and most display features are controlled by either the five button keypad on the PIDD or by the MODE/SET 1 switch on the left hand control. Please see your PIDD Owner’s Manual for more information. This manual is frequently updated for accuracy and new features.
When using the recommended 91 non-ethanol gasoline, always select the 91 NON-ETHANOL setting. When using ethanol, MTBE, or other forms of oxygenated gasoline, the fuel type must be changed to NON-PREMIUM/ETHANOL in the gauge.
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.
Start the engine.
Press and hold the center button to enter the Options Menu.
Press and release the MODE button until FUEL TYPE is displayed in the information display area.
Press and release the SET button to toggle through available options until the desired fuel type is displayed in the information display area.
Press and release the MODE button until EXIT appears in the information display area.
If your model is equipped with the POLARIS interactive digital display (PIDD), please see your PIDD Owner’s Manual for fuel type selection procedures.
The over-temperature indicator on the standard instrument cluster will illuminate when the engine is overheating. Take action to cool the engine. See the Engine Cooling Actions section for more information. The indicator will flash when engine temperature reaches critical levels. Stop the engine immediately.
The engine temperature scale 1 located on the right side of the PIDD screen changes to RED and the check engine temperature indicator 2 located on the top left of the screen illuminates when the engine is overheating. Take action to cool the engine. See the Engine Cooling Actions section for more information. The indicator will flash when engine temperature reaches critical levels. Stop the engine immediately.
Please see your PIDD Owner’s Manual for more information.
|
Engine Temperature Protection Modes |
|
|---|---|
|
Hot Lamp |
Threshold* |
|
ON |
Lamp illuminates: Idle = 201° F (94° C), WOT = 185° F (85° C) |
|
FLASHING |
Lamp Flashes, Engine Turns Off: Idle = 215.6° F (102° C), WOT = 201° F (94° C) |
|
* Only the minimum (idle) and maximum (WOT) parameters are listed. |
|
Flashing indicators indicate continued operation could result in serious engine damage. The engine management system will automatically reduce engine power and create a misfire condition. Stop the engine immediately. Allow the engine to cool down.
If the engine is overheating, promptly take action to cool the engine.
Drive in loose snow.
View the coolant level. Do not open the pressure cap while the engine is hot.
Stop the engine and allow it to cool down.
Add coolant if the level is low. Do not add coolant while the engine is hot. Wait for the engine to cool before adding coolant.
The front and rear suspensions on your snowmobile are easy to adjust. Just remember three simple steps:
Ride your snowmobile.
Adjust the shock spring preload to tune vehicle balance (ski pressure and weight transfer).
Adjust torsion spring settings to regulate weight transfer.
Step 1: Ride your snowmobile.
Ride the snowmobile in various terrain to fully experience the existing suspension settings before making any adjustments. After riding, you should be able to determine if the snowmobile needs more or less transfer.
Step 2: Adjust the shock spring preload to tune vehicle balance.
For more transfer, decrease the shock spring preload.
For less transfer, increase the shock spring preload.
Step 3: Adjust the torsion spring settings to regulate weight transfer.
For more transfer, decrease the torsion spring setting.
For less transfer, increase the torsion spring setting.
If you prefer your snowmobile has lighter steering, decrease the torsion spring setting or increase the front track shock spring preload.
Test ride the snowmobile and continue making spring and clicker adjustments until you achieve the perfect ride.
1 Independent Front Suspension (IFS) Shock
2 Front Track Shock
3 Rear Track Shock
The primary adjustment for overall vehicle balance is torsion spring preload. Perform this adjustment first. After adjusting torsion spring preload to your satisfaction, compression damping adjustments can be made to control ride quality and bottoming resistance.
Compression damping can be adjusted at the front suspension and at the front and rear track shock. Make adjustments in 2-click increments, then test ride. When adjusting the front suspension, always 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 a more 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 achieved.
Always perform shock spring preload adjustments with the weight of the vehicle removed from the shock and with the shock at full extension.
|
Model |
Factory Install Length |
Minimum Installed Length |
Maximum Installed Length |
|---|---|---|---|
|
INDY SP |
3.875 in (9.842 cm) |
4.380 in (11.120 cm) |
3.875 in (9.842 cm) |
|
RMK 144 |
4.25 in (10.795 cm) |
4.75 in (12.065 cm) |
4.25 in (10.795 cm) |
To improve cornering ability, remove up to 1/2 in of preload from factory IFS spring setting. Trade-off for removing 1/2 in of preload will add steering effort.
Factory settings, combined with user adjustments to the rear torsion spring, should be all that’s necessary to provide the best riding experience for most riders. The primary adjustment for overall vehicle balance is the rear torsion spring preload. Perform this adjustment first.
Always perform shock spring preload adjustments with the weight of the vehicle removed from the shock and with the shock at full extension.
Never adjust spring preload to an installed length longer than the factory length or shorter than the minimum length as shown in the following chart. Damage to the suspension could result. When decreasing preload, make sure at least two turns of preload are holding the retainer against the spring.
|
Model |
Factory Install Length |
Maximum Installed Length |
Minimum Installed Length |
|---|---|---|---|
|
Indy SP |
1.5 in (3.8 cm) |
2 in (5.1 cm) |
1.5 in (3.8 cm) |
|
RMK 144 |
1.875 in (4.762 cm) |
2.375 in (6.032 cm) |
1.875 in (4.762 cm) |
To adjust rear torsion spring preload, rotate the three-position cam 1 using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more effort. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information.
| Torsion Spring Setting | Recommended Usage |
|---|---|
| Low |
Rider(s) and gear =140-180lb If less than 140, use the optional spring chart for softer springs. |
| Medium |
Rider(s) and gear = 180-220lb |
| High |
Rider(s) and gear = 220-260lb If above 260, use the optional spring chart for heaver springs. |
|
Kit Number |
Spring Type |
Description |
Fitment (By Track Length) |
|---|---|---|---|
|
2884973 |
Spring, Torsion |
Light Duty |
129/137 |
|
2884974 |
Spring, Torsion |
Heavy Duty |
129/137 |
|
2884975 |
Spring, Torsion |
Extra Heavy Duty |
129/137 |
|
2884976 |
Spring, Torsion |
Light Duty |
600 RMK 144 |
|
2884977 |
Spring, Torsion |
Heavy Duty |
600 RMK 144 |
Moving the RRSS to a higher position will have the following effects on the suspension:
Reduced weight transfer
Improved chatter bump ride
Improved cornering performance
Increased load carrying capacity (2–up)
The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions.
To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position.
To increase weight transfer or ski lift during acceleration, rotate the RRSS to a lower position.
1 High
2 Medium
3 Low
4 Low
The front torque arm limiter strap
is factory set at position 1.
Polaris recommends leaving the limiter strap length at position 1 to maintain the optimum ride characteristics of the snowmobile.
Riders who desire less ski pressure and more weight transfer toward
the rear of the snowmobile can lengthen the limiter strap by changing
to position 2.
Loosen the lock nut.
Adjust the limiter strap.
Tighten the lock nut.
Lock Nut
16 ft-lbs (21 N·m)
Moving a handlebar component without first loosening its screws/set screws may cut grooves into the handlebar, making it difficult to secure the component. DO NOT move a handlebar component without first loosening its mounting screws/set screws. Take care to avoid damaging hand warmer/brake switch wires when moving components.
| Component | Torque DO NOT OVER-TIGHTEN |
|
|---|---|---|
| 1 | Left Handlebar Control Block |
20 in-lbs (2.3 N·m) |
| 2 | Brake Lever / Master Cylinder Torque the front screw first, then torque the screw next to the reservoir. |
70 in-lbs (7.9 N·m) |
| 3 | Upper / Lower Riser Clamps |
14.8 ft-lbs (20 N·m) |
| 4 | Throttle Lever Block Set Screw |
27 in-lbs (3.1 N·m) |
| 5 | Throttle Lever Block Cover Screws |
6 in-lbs (0.7 N·m) |
| 6 | Auxiliary Engine Stop Switch Set Screw |
12 in-lbs (1.4 N·m) |
| 7 | Riser | Install with the “FWD” stamp facing toward the hood |
| Not Shown | Hand Guard Mounts (if applicable) | Hand-Tight |
| Not Shown | Mountain Hoop Bar (if applicable) |
10 ft-lbs (13.6 N·m) |
Handlebar angle can be adjusted to suit rider preference.
Adjust the handlebar upward or downward to the desired angle. Be sure the handlebar, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right. If necessary, loosen the set screws for the left and right controls, rotate the controls slightly, then tighten the set screws to the proper torque.
Do not stretch wires while adjusting the controls. Stretching the wires could damage the handwarmers.
Tighten the bolts.
14.8 ft-lbs (20 Nm)
Riser angle can be adjusted to suit rider preference.
Loosen the four bolts on the bottom of the adjuster block 2. If necessary, pry the blocks apart with a screwdriver.
Adjust the riser forward or rearward to the desired position.
Tighten the bolts to 14.8 ft-lbs (20 Nm).
The height of the handlebars can be adjusted if your snowmobile is equipped with an optional ROX® Adjustable Bar Riser.
Use the following instructions to raise and lower your handlebars.
Release the riser clamp 1.
Adjust the handlebar upward or downward to the desired height.
Secure the riser clamp 1.
Handlebar Clamp Fastener Torque
16 ft-lbs (21 N·m)
ROX® Slide Fastener Torque
16 ft-lbs (21 N·m)
Adjuster Cranks
Hand Tight
The following procedure details how to properly align the left hand control block.
Loosen the brake master cylinder 1 mounting screws and move it away from the left hand control.
Loosen the four left hand control mounting screws.
Move the control block to the desired position.
Tighten the screws to specification in the sequence shown in the image. Do not over-torque.
Control Block Mounting Screws 2 - 5
24 in-lbs (2.7 N·m)
Return the master cylinder to its specified position. Make sure the clamp will not pinch the brake light signal wire. Tighten the mounting screws 1 to specification beginning with the front screw first, then the screw next to reservoir. Do not over-torque.
Master Brake Cylinder Mounting Screws 1
70 in-lbs (7.9 N·m)
Use the illustration and table below to determine the factory-set placement locations of the handlebar components. Locations are determined by measuring the distances between each component and the overall handlebar length.
Do not move handlebar components without first loosening the components’ screws.
| 1 0.11 in (3 mm) | 4 0.11 in (3 mm) |
| 2 0.47 in (12 mm) | 5 0.08 in (2 mm) |
| 3 10 in (254 mm) | 6 6.7 in (170 mm) |
Take care to avoid damaging hand warmer wires when moving components.
Slightly loosen the set screw 1 on the bottom of the housing.
Move the control block to the desired position.
Tighten the screw to specification. Do not over-torque.
With the engine off, test throttle lever movement after tightening the screw. See Throttle Safety Switch.
Control Block Screw
27 in-lbs (3 N·m)
The stop switch must be positioned in an easily accessible location.
Slightly loosen the set screw on the bottom of the housing 2.
Move the switch to the desired position.
Tighten the screw to specification. Do not over-torque.
Stop Switch Set Screw
12 in-lbs (1.4 N·m)
Track studding will enhance braking control on hard-packed snow or ice, but extreme caution is still required on such surfaces. Steering ability may be reduced on hard-packed snow or ice.
When studded tracks are used, increased wear to the brake pads will result from increased braking and requires increased brake inspection intervals.
Installing studs can also cause the track to stretch more than a non-studded track. For this reason, POLARIS recommends inspecting track tension more often and setting the tension at the preferred measurement.
Always adhere to the manufacturer’s stud maintenance procedures and stud nut torque specifications.
Before equipping your snowmobile with traction products, be aware of regulations pertaining to the use of traction products in your area of operation.
Track damage resulting from improperly installed or maintained studs is not covered under warranty. Use only Polaris-approved traction products on your snowmobile. See your dealer for more information about installing studs and/or carbides.
Failure to heed the following recommendations will result in tunnel or track damage:
Use of studs longer than the recommended length on snowmobiles equipped with center coolers will result in center cooler damage or damage to the tunnel.
Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the specification to prevent heat exchanger damage. The center of the stud must be at least 1 1/8 inch (2.9 cm) from any edge of the track, including track window.
Studding the outside band of the track diminishes durability.
Polaris does not recommend studs down the center line of the track to prevent shock damage.
Polaris does not recommend studs on the outside band of the Storm 150 track. Damage will occur.
The AXYS Indy 129 chassis requires stud protection kit 2883572 to be installed before installing studs or chassis damage will occur. This stud protection kit will protect against chassis damage with the following track/stud combinations.
1.325 in Polaris/Woody’s® studs installed in a Ripsaw II 1.25 in or Cobra 1.352 in track .
1.575 in Polaris/Woody’s® studs installed in a Storm 150 track, center band only.
1 Penetration Range: 1/4 - 3/8 in (6-9 mm)
2 Stud Size
3 Track Lug Height
4 Track Belt Thickness
|
Maximum Penetration |
|||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|
|
POLARIS Studs |
Stud Length |
1.25-Inch (3.2 cm) Track |
1.352-Inch |
Overall Installed Height |
Recommended for AXYS models |
||||||
|
in. |
cm |
in. |
cm |
in. |
cm |
in. |
cm |
||||
| Signature Series |
1.325 |
3.4 |
.375 |
.95 |
.27 |
.7 |
1.58 |
4.0 |
YES |
||
| Signature Series |
1.45 |
3.7 |
- |
- |
- |
- |
1.7 |
4.3 |
NO |
||
Failure to heed the following recommendations will result in tunnel or track damage and a voided warranty.
The track is not warranted by POLARIS if studs have been installed. Track warranties are also void if track damage or failure results from the use of any non-POLARIS traction products. Use only POLARIS-approved traction products on your snowmobile. See your dealer for more information about installing studs and/or carbides.
Use of studs longer than the recommended length on snowmobiles equipped with center coolers will result in center cooler damage or damage to the tunnel.
1 Penetration Range 1/4 - 3/8 in (6-9 mm)
2 Stud Size
3 Track Lug Height
4 Track Belt Thickness
| Track | Track Length | Stud Kit Part Number |
Lug Height | Stud Quantity |
|---|---|---|---|---|
| Cobra | 137 | 2884200 | 1.352/1.25" | 96 |
Track studding will enhance braking control on hard-packed snow or ice, but extreme caution is still required on such surfaces. Steering ability may be reduced on hard-packed snow or ice.
When studded tracks are used, increased wear to the brake pads will result from increased braking and requires increased brake inspection intervals.
Installing studs can also cause the track to stretch more than a non-studded track. For this reason, POLARIS recommends inspecting track tension more often and setting the tension at the preferred measurement.
Always adhere to the manufacturer’s stud maintenance procedures and stud nut torque specifications.
Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the specification to prevent heat exchanger damage. The center of the stud must be at least 1 1/8 in (2.9 cm) from the outside edge of the track.
Before equipping your snowmobile with traction products, be aware of regulations pertaining to the use of traction products in your area of operation.
A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper steering and control. See Skag Replacement.
Maintain a proper balance between the number of studs and the length of carbide on the skags (the more studs you use, the longer the carbide on the skags should be). See your dealer's track studding chart.
Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined in the referenced sections.
|
Item |
See Section |
|---|---|
|
Drive Belt |
|
|
Steering System |
|
|
Recoil Rope |
|
|
Coolant Level |
|
|
Chaincase Oil Level (if equipped) |
|
|
Injection Oil Level |
|
|
Parking Brake Lock/Brake Lever/Brake System |
Brakes, Parking Brake Lever Lock, and Hydraulic Brake Inspection |
|
Auxiliary Shut-Off Switch (Engine Stop Switch) |
|
|
Ignition Switch |
|
|
Headlight/Taillight/Brakelight |
|
|
Suspension Mounting Bolts |
|
|
Skags (Wear Bars) |
|
|
Ski Saddle and Spindle Bolts |
|
|
Hood and Side Panel Fasteners |
|
|
Throttle Lever/Safety Switch |
|
|
Rear Wheel Idler Bolt |
|
|
Tether Switch/Strap (if equipped) |
|
|
Track Alignment/Condition |
Track and Track Alignment |
|
Rail Slide Condition |
Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip.
|
Item |
See Section |
|---|---|
|
Check suspension mounting bolts for tightness. |
- |
|
Check rear idler wheel bolt for tightness. |
|
|
Check rear idler adjusting bolt locknuts for tightness. |
- |
|
Check front torque arm limiter strap condition. |
- |
|
Check rail slide condition. |
|
|
Check track tension. |
|
|
Check ski runner/skag condition. |
|
|
Check ski spindle bolts for tightness. |
- |
|
Check tie rod end nuts for tightness. |
- |
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.
Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable snowmobiling experience.
The throttle and brake are the primary controls of your snowmobile. Always make sure both are functioning properly.
Squeeze the throttle lever to make sure it compresses evenly and smoothly. When released, the lever should immediately return to the idle 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.
Test the throttle safety switch system before the snowmobile is operated.
Always check the following items for proper operation before starting the engine.
Squeeze the brake lever. It should move no closer to the handgrip than 1/2 inch (1.3 cm) 1. A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information in the Hydraulic Brake Inspection section. An authorized POLARIS dealer can assist.
If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See the Brake Fluid section for details.
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 five minutes or less.
1 Brake Lever
2 Parking Brake Lever Lock
3 Master Cylinder Reservoir/Cover
To engage the lock, squeeze the brake lever tightly and push forward on the lock. Hold the lock forward while releasing the brake lever.
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 authorized POLARIS dealer.
To release the lock, squeeze the brake lever tightly. The lock will return to the unlocked position.
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.
Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty.
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.
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, your authorized POLARIS dealer can provide a replacement.
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.
Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting.
Make sure the engine stops when the ignition switch is turned to OFF.
If your snowmobile has a tether switch, remove the tether from the switch to make sure the engine stops immediately.
Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating.
Adjust the mirrors so they can be used to their full advantage.
Before driving away, check your surroundings. Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile.
Turn the key to the ON position.
Pull the engine stop switch up to the RUN position.
If equipped with electric start, turn the key to START to crank the engine. Release the key to the ON position when the engine starts.
If not equipped with electric start, grasp the starter handle and pull slowly until the recoil engages; then pull abruptly to crank the engine.
If the engine does not start after several attempts, slightly depress the throttle no more than 1/4 inch (2.54 cm) open while cranking the engine. When the engine starts, immediately release the throttle.
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:
Push the engine stop switch down to the OFF position.
Turn the key to the OFF position.
With both switches OFF, squeeze and hold the throttle in the wide open position.
Crank the engine several times to clear the engine.
Release the throttle.
Restart the engine using the normal starting procedure.
Engines equipped with an electronic oil pump do not require initial fuel premix.
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 parts, allowing them to break in slowly without damage.
The AXYS engine management system utilizes both a fuel injector break-in period and oil pump enrichment program. The duration of these break-in programs are independent of each other and are timed-out based on engine run-time. Regardless of these automatic engine break-in / enrichment features, the following engine break-in procedures must be performed when the engine is new or overhauled.
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.
Drive with extra caution during the break-in period. Perform regular checks on fluid levels, lines, and all other important areas of the snowmobile.
| Break-In Function | Engine Run Time Duration | Description |
|---|---|---|
| Fuel Injectors | 2 hours * | 5% additional fuel |
| 600 AXYS Engine Oil Pump Enrichment Period | 5 Hours * | 5% additional enriched oil supply to engine |
| * = Total engine run time above 5,500 RPM | ||
Always check and fill the oil bottle during pre-ride inspection and refueling.
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 authorized POLARIS dealer or other certified technician immediately.
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.
New drive belts should be washed with warm, soapy water and allowed to air dry prior to 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.
It is very important to inspect and adjust track tension after every ride for the first 150 mi (240 km) of use to ensure the proper tension during the break-in period. Aggressive riders in certain snow conditions may need to adjust track tension as early as 20 mi (32 km). After the break-in period track tension should be inspected every 150 mi (240 km).
Early wear can be caused by two conditions – improper track tension and/or sustained trail riding at high speeds without scratchers. Neither condition results from a defect in the track, and wear caused by either or both of these conditions is not covered by warranty.
Loose tracks reduce drive system efficiency because:
Track tension constantly varies on snowmobiles as the rear suspension extends and compresses.
Loose track tension increases the chance for the drive shaft to ratchet in high load driving modes. Track ratcheting may damage the track and drive nubs.
Loose track tension decreases rail slider life and can cause uneven slider wear.
The slack in a loose track bows out in front of the rail tips. This bowing effect significantly reduces drive system efficiency, creates drag, and changes the approach angle of the rear suspension, which decreases the snowmobile's ability to get on top of the deep snow.
Follow these steps to ensure proper warm-up of the engine, drive train and track.
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.
Start the engine and allow it to warm up two to three minutes.
Depress the throttle abruptly and allow the track to rotate several revolutions.
Release the throttle, apply the brakes, shut off the engine and lower the snowmobile to the ground.
Grasp the skis by their front loops and move them from side to side to loosen snow and ice.
Always exercise extreme caution whenever handling gasoline.
Always refuel outdoors or in a well-ventilated area.
Always turn off the engine before refueling.
Do not overfill the tank. Do not fill the tank neck.
Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.
Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time.
For peak performance, POLARIS recommends the use of 91 octane fuel or higher, with no ethanol. 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 or 88 E15 fuel in your snowmobile.
For peak performance, POLARIS recommends the use of 95 octane E10 gasoline or higher octane. If lower octane is used, some engine performance will be lost and fuel economy will decrease. Do not use gasoline with higher ethanol rating than E10.
If you use non-ethanol fuel (sometimes labeled “non-oxygenated”), POLARIS recommends the regular use of isopropyl-based fuel system deicer. Add 1-2 ounces per gallon (8-16 ml per liter) of gasoline to prevent damage resulting from fuel system icing. Never use deicers or additives containing methanol. POLARIS recommends the use of Carbon Clean.
Polaris Recommended Engine Oil
VES 2-Cycle Full Synthetic Engine Oil
For peak performance, Polaris recommends the use of VES 2-cycle full synthetic engine oil.
For high performance operation, or operation in arctic conditions (-40°C/-40°F), use VES Extreme 2-cycle full synthetic engine oil
In lieu of VES-branded oil, substitute with Polaris Blue 2-cycle synthetic blend engine oil.
Always maintain the oil level between the “add” mark and the bottle neck. Do not fill the bottle neck.
Immediately stop the engine if the low oil indicator light comes on.
Open the left side panel.
View the oil level in the oil bottle.
Add oil as needed before operating.
The oil bottle cap is vented to allow proper oil flow. Your POLARIS dealer can assist with recommended replacement parts.
If the engine stops abruptly when the throttle lever is released:
Turn the ignition switch to OFF.
Visually inspect the throttle cable and carburetor/throttle body to determine what caused the safety switch to activate.
Test the throttle lever by compressing and releasing it several times. The lever and cable must return to the idle position quickly and completely.
If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures.
If the engine doesn't start, your authorized POLARIS dealer can perform this 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.
Push down on the engine stop switch 1 to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting.
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.
Operating 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.
Sit on the seat.
Start the engine and allow it to idle.
Hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration.
Apply a slight amount of throttle. A properly functioning switch must shut down the engine.
Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle.
Look behind the vehicle before and while backing.
Avoid sharp turns.
Apply throttle slowly.
Electronic reverse will activate only if the engine RPM is below 3000.
Stop the snowmobile and leave the engine idling.
Make sure the area behind your vehicle is clear.
Push the yellow 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.
Apply the throttle slowly to make sure the transmission is in reverse. The maximum engine RPM will be 5000 when in reverse.
Stop the snowmobile and leave the engine idling.
Push the 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.
Apply the throttle slowly to make sure the vehicle is in forward.
The following chart lists methods for stopping the snowmobile in the event of an emergency.
|
SYSTEM |
WHAT IT DOES |
|---|---|
|
Ignition Switch |
Interrupts ignition circuit |
|
Brake |
Slows jackshaft |
|
Engine Stop Switch |
Interrupts ignition circuit |
|
Throttle Safety Switch |
Interrupts ignition circuit |
|
Tether Switch (Option) |
Interrupts ignition circuit |
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.
For your safety, do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions.
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 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.
Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions related service, however equivalent parts may be used for such service. 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.
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.
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 an authorized POLARIS dealer for diagnostic service. Specifications 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.
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, or other qualified person, to perform any service that may be necessary.
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.
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 Maintenance Log.
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 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, your authorized POLARIS dealer can provide any needed service.
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.
| Periodic Maintenance Schedule | |||||
|---|---|---|---|---|---|
| Item | Frequency / Intervals | ||||
| 150 mi. (240 km) |
500 mi. (800 km) |
1000 mi. (1600 km) |
2000 mi. (3200 km) |
Pre-Season | |
| L = Lubricate / I = Inspect or Adjust / R = Replace / C = Clean | |||||
| Drive / Driven Clutch | |||||
| Clutch Alignment / Offset | I | I | I | I | |
| Drive Belt Condition / Ride Out | Pre-Ride Inspection | I | |||
| QUICKDRIVE Belt (If Equipped) | I | I | I | R | I |
| Drive / Driven Clutch Condition | I | C | I | I | C |
| Drive Belt Tension | I | I | I | I | |
| Engine | |||||
| Engine Mounts | I | I | I | I | |
| Recoil Handle / Rope / Function | I | I | I | I | |
| Cylinder Head Bolts | I | I | I | ||
| Cylinder Base Nuts | I | I | I | ||
| Ignition Timing BTDC | I | I | I | ||
| Spark Plugs | I | I | R | I | |
| Exhaust Pipe | I | I | |||
| Exhaust System Retaining Springs | I | I | I | I | |
| VES System (600 Engine Only) |
C (clean at 1500 MI/2414 KM) |
I | |||
| Coolant Level | Pre-Ride Inspection | I | |||
| 50/50 Extended Life Coolant | Replace every 5 years | ||||
| 60/40 Coolant (If applicable) | Replace every 2 years | ||||
| Cooling Hoses / Pipes | I | I | I | I | |
| Brake System | |||||
| Brake Lever | Pre-Ride Inspection | ||||
| Hose Condition / Routing | I | I | I | I | |
| Fluid Level / Leaks / Fluid Condition | I | I | I | I | |
| Brake Pads / Brake Disc | I | I | I | I | |
| Parking Brake | Pre-Ride Inspection | ||||
| Brake System | I | ||||
| Brake Fluid | R | ||||
| Fuel System | |||||
| Throttle Lever / Throttle Cable | I | I | I | I | I |
| Fuel / Vent Hoses | I | I | I | I | |
| Oil Hoses | I | I | I | ||
| Air Box | I | I | I | I | I |
| Electrical System | |||||
| Auxiliary Shut-Off | Pre-Ride Inspection | I | |||
| Throttle Release Switch | Pre-Ride Inspection | I | |||
| Ignition Switch | Pre-Ride Inspection | I | |||
| Headlights / Brake light / Taillights | Pre-Ride Inspection | I | |||
| Hand / Thumbwarmers | Pre-Ride Inspection | I | |||
| PERC Reverse System | Pre-Ride Inspection | I | |||
| Chassis / Suspension | |||||
| Ski Toe Alignment | I | I | I | ||
| Front / Rear Suspension Mounting Bolts | Pre-Ride Inspection | ||||
| Steering Fasteners / Linkage / Handlebars | Pre-Ride Inspection | ||||
| Ski Fasteners | Pre-Ride Inspection | C | |||
| Ski Skags | Pre-Ride Inspection | ||||
| Hood / Side Panel Fasteners | I | I | I | I | I |
| Drive Chain Tension (If Equipped) | I | I | I | I | I |
| Chaincase Oil (If Equipped) | I | R | I | R | I |
| Track Alignment / Track Tension | I | I | I | I | I |
| Front Limiter Strap | I | I | I | I | I |
| Rail Slide Condition | I | I | I | I | I |
| Rebuildable IFP Shock Oil | R | ||||
| Rear Shock Threads | L | ||||
| Bogie / Wheel Condition / Fastener Bolts | I | I | I | I | I |
| Rear Idler Wheel Bolts | I | I | I | I | I |
| Rear Idler Adjuster Bolt Jam Nuts | I | I | I | I | I |
| Cooling Fins and Shroud | I | I | I | I | |
| Camber Alignment | I | I | I | ||
| Handlebar Centering | I | ||||
| Hood / Seat / Chassis / Engine Compartment | C | C | |||
Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on Periodic Maintenance Chart 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. For more information about suspension lubrication and adjustments, see your POLARIS dealer.
Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning pages. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube, or equivalent product.
Position the snowmobile on a level surface.
Remove the fill plug.
Using a funnel, slowly add the recommended oil until the fluid begins to overflow.
Clean the area with a clean, dry shop towel. Reinstall the fill plug.
Fill Plug
4-4.9 ft-lbs (5.4-6.6 Nm)
This procedure requires the use of a commercially available hand pump oil extractor.
Elevate the front of the snowmobile using a floor jack or appropriate lift.
Remove the fill plug. Clean all metal shavings off the plug.
Insert the tube of a hand pump oil extractor into the fill hole. Direct the hose toward the bottom front area of the cover, away from the chain/sprocket.
Extract the oil from the chaincase.
Lower the snowmobile.
Using a funnel, slowly add the recommended oil until the fluid begins to overflow. Maximum fluid capacity is 10.5 oz. (310 ml).
Clean the area with a clean, dry shop towel.
Reinstall the fill plug.
4-4.9 ft-lbs (5.4-6.6 Nm)
Position the snowmobile on a level surface.
Remove the two (2)screws securing the fender to the chaincase 1.
Remove the right side panel. If equipped with a battery, remove the battery.
Place a drain pan under the chaincase.
Loosen (do not remove) the three (3) chaincase cover screws 2.
Carefully pry the cover open.
DO NOT insert a screwdriver or pry bar between the cover and chaincase. Seal damage may occur.
Allow the oil to drain completely.
Tighten the cover screws 2.
6-10 ft-lbs (8-13 Nm)
Remove the fill plug 3. Clean all metal shavings off the plug.
Using a funnel, slowly add the recommended oil until the fluid begins to overflow. Maximum fluid capacity is 10.5 oz. (310 ml).
Clean the area with a clean, dry shop towel.
Reinstall the fill plug 3.
4-4.9 ft-lbs (5.4-6.6 Nm)
Reinstall the battery(if equipped).
Reinstall the screws securing the fender to the chaincase.
Inspect oil line condition every 1000 miles (1600 km).
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 the lower edge of the panel. To remove an open side panel, pull the panel outward to release the tabs at the lower edge of the panel.
To remove the hood, do the following:
Remove the left and right side panels.
Rotate the 1/4 turn fasteners 1 at the rear corners if the hood.
Disconnect the hood wire harness connector 3.
Remove the hood assembly from the vehicle.
The intake foam filters 1 limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow.
All fuel pump service must be performed by an authorized POLARIS dealer. Do not attempt to service the fuel pump.
This snowmobile is not equipped with an in-line fuel filter. The fuel pump uses a sock-type pickup filter located within the fuel tank. This filter should only require maintenance if debris or foreign material enters the fuel tank. An authorized POLARIS dealer can provide service.
Contaminated or poor quality fuel may shorten the life of fuel system components and result in poor engine performance. Always store fuel in clean fuel containers. If low fuel pressure or reduced engine performance occurs, the filter may need replacement. An authorized POLARIS dealer can assist.
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.
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.
A new engine can cause temporary spark plug fouling due to the lubricant added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization.
Refer to the Specifications chapter for the specific spark plug to be used in your snowmobile.
Change the spark plugs at the intervals outlined in the Periodic Maintenance section.
Use recommended spark plugs with the proper gap. Refer to the specifications section for the specific spark plug to be used in your snowmobile.
Use only resistor-type spark plugs.
Torque spark plugs to specification.
Spark Plug
18-22 ft-lbs (24-30 N·m)
Always carry spare spark plugs.
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.
Remove the left side panel and hood.
Remove the spark plug cap.
Using the spark plug wrench provided in the tool kit, rotate the spark plug counter-clockwise to remove it.
Reverse the procedure for spark plug installation. Torque to specification.
Reinstall the spark plug cap. Verify an “audible” click is heard when installing the plug cap.
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.
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.
POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. If the vehicle will be stored or operated at extremely low temperatures, greater protection may be required. An authorized POLARIS dealer can assist.
To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely flushed and drained every five (5) years and fresh Antifreeze 50/50 Premix.
Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix.
The engine coolant level is controlled by the recovery system. The recovery system components are:
Coolant bottle/overflow tank
Pressure cap
Connecting hoses
Always maintain the coolant level at or slightly above the FULL COLD mark on the coolant bottle (when the engine is cold).
Stop the engine.
Open the right side panel.
View the coolant level in the coolant bottle. Add coolant as needed.
Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage. Always maintain the coolant level as recommended.
To ensure that the coolant maintains its ability to protect the engine, Polaris recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added. This service must be performed when the engine is cold. Your authorized POLARIS dealer can check the coolant when performing the fall tune-up on your snowmobile.
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.
Severe engine damage may occur if the cooling system becomes restricted or plugged or contains trapped air pockets.
Perform this procedure in a well-ventilated area. Use the recommended coolant. See Coolant.
Open the side panels and remove the hood.
Close the side panels.
Never operate a snowmobile with the side panels open or removed.
Position the snowmobile with the right ski and control arms elevated at a 45-degree angle.
Fill the coolant bottle to the COLD FILL mark.
Install the coolant bottle cap to the first lock. Do not tighten to the fully seated position.
Lock the parking brake.
Start the engine and allow it to run at a fast idle for several minutes, until the tunnel coolers are warm to the touch. Loosen the bleed screw occasionally to purge any trapped air.
When all tunnel extrusions are warm to the touch, stop the engine.
Allow the engine and cooling system to cool. Secure the bleed screw.
Fill the coolant bottle to the COLD FILL mark. Reinstall the bottle cap securely.
Carefully lower the front end of the snowmobile.
Open the side panels and reinstall the hood. Close the side panels.
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.
Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running.
Open the side panels and remove the hood.
Inspect the muffler and pipes for cracks or damage.
Check for weak or missing retaining springs or damper/support grommets.
Check for loose clamps on the pipe covers.
Reinstall the hood and side panels.
Check drive chain tension weekly and before each long trip.
Remove the side panels.
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.
Loosen the adjuster bolt jam nut 1.
Finger tighten the adjuster bolt 2 until it can no longer be adjusted by hand, then back off 1/4 turn.
Tighten the jam nut while holding the adjuster bolt.
21 ft. lbs. (28 Nm)
Reinstall the side panels.
Release the brake lever lock.
Inspect the brake lever reserve before each use of the snowmobile. See Brake Lever Travel.
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. Your POLARIS dealer can assist.
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 than the backing plate (approximately 1/16 inch or 1.5 mm).
1 Brake Caliper
2 Brake Disc
3 Brake Pad Material
Replace when
thickness is less than 1/16 in
(1.5 mm).
Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, bring the snowmobile to an authorized POLARIS dealer for inspection and adjustment.
Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid, or an equivalent product.
Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile.
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.
Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running.
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.
Remove the brake master cylinder reservoir cover and gasket.
Fill the master cylinder reservoir to 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir opening. Reinstall the gasket and cover.
Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container.
Squeeze the brake lever a full stroke. Then unscrew the bleeder valve 3/4 of a turn to release air.
Close the bleeder valve and release the brake lever.
Repeat steps 4–5 until fluid flows from the bleeder valve in a solid stream free of air bubbles.
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 fluid to the fill line as recommended.
After bleeding is complete, refill the reservoir to the proper level. See Brake Fluid.
Reinstall the gasket and cover.
The headlight and taillight assemblies feature LED elements and are not serviceable. If an LED fails to illuminate in either the headlight or taillight, the entire assembly must be replaced.
If the engine stops or will not start, or if an electrical component fails to operate, a fuse may need replacement. Locate and correct any damage or short circuits that may have caused the blown fuse, then replace the fuse.
Always replace a blown fuse with a new fuse having the same amperage rating of the blown fuse. Never replace a fuse with a fuse of a higher amperage rating.
Models equipped with electric start or an IDD have a battery/electric start wire harness. The 2 amp constant power fuse is located in the hood harness. This fuse protects KEY ON power at the ignition switch. KEY ON power supplies battery voltage to the IDD and GPS puck.
If the IDD does not turn on when the key is in the ON position, check for a blown fuse. If the fuse is blown, inspect the constant power circuit. Repair or replace any damaged components before replacing the fuse.
Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol.
All clutch maintenance and repairs can be performed by an authorized POLARIS dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty.
Clutch alignment offset is important for maintaining optimum performance. Your authorized POLARIS dealer can perform service and adjustments. A special tool is required to check for proper alignment.
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.
Always carry a spare drive belt. When placing the belt in the holder, orientate the belt to match the profile 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.
Measure belt deflection with both clutches at rest and in their full neutral position.
Place a straight edge on the belt and apply downward pressure while measuring at point. This measurement should be 1 1/4 inches (3.2 cm).
To adjust the drive belt, do the following:
Loosen the driven clutch set screw with 7/16 wrench.
Using an 1/8 in Allen® wrench, adjust set screw until belt deflection meets specification.
Holding set screw with Allen® wrench, lightly tighten nut.
Using the L-wrench, open driven clutch sheaves 0.5 in.
Tighten deflection screw nut to specification.
Deflection Screw Nut
145 in-lbs (16.4 N·m)
Rotate belt clockwise while removing L-wrench.
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.
Stop the engine after operating in a forward motion.
Turn the ignition key off. Wait for the engine to come to a complete stop.
Lock the parking brake.
Remove the left side panel.
Rotate the driven clutch counter-clockwise 1/4 turn by hand to ensure forward engagement.
Locate the L-wrench in the tool kit. Install the wrench into the open threaded hole in the outer sheave of the clutch.
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.
Remove the belt from the driven clutch.
With the L-wrench inserted into the threaded hole and the sheaves in the open position, install the drive belt.
Install the belt so that the numbers can be read correctly on the left side of the vehicle, or in the direction in which the belt was originally installed.
Rotate the belt clockwise to remove slack while removing the L-wrench.
Reinstall the side panel.
Break in the new belt. See Drive Belt Break-In.
Using a hoist, safely lift and support the rear of the snowmobile off the ground.
Rotate the track by hand to check for damage.
Carefully examine the track along the entire length of each rod 1. Bend the track to check for breakage.
Replace the track if any rod damage is found.
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.
If excessive rail slide wear occurs due to poor snow conditions, additional wheel kits are available. Your authorized POLARIS dealer can provide more information.
Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty.
Track adjustment is critical for proper handling. Always maintain correct tension and alignment.
|
TRACK TENSION DATA CHART |
|||
|---|---|---|---|
|
Suspension |
Slack Measurement |
Weight |
Measurement Location |
|
All Models |
7/8-1 1/8 inch (2.2-2.6 cm) |
10 lbs. (4.54 kg) |
16 inches (40 cm) ahead of rear idler shaft |
Tension adjustments should be made only after the track is warmed up and limber.
Turn the engine off.
Lift the rear of the snowmobile and safely support it off the ground.
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.
Measure at the point where the weight is hanging.
Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart above.
If the track needs adjustment:
Loosen the rear idler shaft bolt.
Loosen the locknuts.
Tighten or loosen the track adjusting screws to provide equal adjustment on both sides of the track.
Repeat the measurement on the other side of the track.
Check more frequently when the snowmobile is new.
Start the engine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brakes).
Check track alignment (see Track Alignment) and adjust as necessary.
Tighten the locknuts.
Tighten the idler shaft bolt.
Idler Shaft Bolt
35 ft-lbs (47.5 N·m)
Periodically check that the track is centered and running evenly on the slide rails 1. Misalignment will cause excessive wear to the track and slide rail.
Safely support the rear of the snowmobile with the track off the ground.
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).
Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side. If the track runs to the left, loosen the idler shaft bolt, then loosen the left locknut and tighten the left adjusting bolt. If the track runs to the right, loosen the idler shaft bolt, then loosen the right locknut and tighten the right adjusting bolt.
After adjustments are complete, tighten the locknuts and torque the idler shaft bolt to specification.
Idler Shaft Bolt
55 ft-lbs (75 N·m)
Repeat steps 2-3 to verify proper alignment.
The steering systems on POLARIS snowmobiles can be adjusted with ski toe alignment. Improper toe alignment can cause erratic steering. Your authorized POLARIS dealer can assist with adjustments.
Each week, or before a long ride, check the following items. If component damage or loose fasteners are found, your POLARIS dealer can provide service.
1 Ski Bolt Nuts
2 Tie Rod End Nuts
3 Upper/Lower Control Arm Nuts (All)
4 Sway Bar Fasteners
5 Shock Mounting Fasteners
6 Lower Control Arm Spindle Nuts
7 Upper Control Arm Spindle Nuts
8 Ski Loop Rear Fasteners
9 Ski Loop Front Fasteners
10 Ski Skag Fasteners
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. Your POLARIS dealer can assist.
Place the handlebars in a straight-ahead position.
With only vehicle weight compressing the suspension, measure 10 inches (25.4 cm) forward from the center of the ski mounting bolt (see 3 in illustration below). At this point, measure between the skis. This is measurement 1.
Perform the same measurement rearward from the center of the ski mounting bolt. This is measurement 2.
The 1 measurement should be 1/8 inch (3 mm) greater than the 2 measurement. If the skis are misaligned, your dealer can assist with alignment correction as camber adjustment may also be affected.
Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. Your dealer's studding chart can provide the 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.
Carbide skags must be replaced if any abnormal wear or chipping is found.
Raise and support the front of the snowmobile so the skis are approximately 6 inches (15.2 cm) from the ground.
Remove the attaching nuts and pry the skag 1 downward.
Remove the front end of the skag.
Remove the rear end of the skag.
Reverse the steps to install a skag.
Polaris rail slides run along the bottom of the rail to prevent track wear. The rail slide should be inspected periodically and replaced when necessary.
For ease of inspection, all POLARIS rail slides have a wear limit indicator groove 2 to indicate the minimum permissible slide thickness 1. 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 in permanent damage to the track or rails.
Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.
CALIFORNIA PROPOSITION 65 WARNING:
Batteries, battery posts, terminals and related accessories can expose you to chemicals including lead, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
Remove the right side panel to access the battery.
Remove the two plastic rivets 1 securing the console panel to the chassis.
Remove the plastic rivet 2 securing the fender to the chassis.
Disconnect the black (negative) battery cable first.
Disconnect the red (positive) battery cable last.
Remove the battery hold-down strap.
Remove the battery shield 3.
Remove the battery from the battery bracket.
When installing a new battery, make sure it's fully charged prior to its initial use. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions before installing the battery.
Ensure that the battery is fully charged.
Set the battery in the battery holder.
Place the battery shield on the battery bracket. Install the screw to secure the shield.
Shield Screw
7 ft-lbs (10 N·m)Install the battery hold-down strap.
Connect and tighten the red (positive) cable first.
Connect and tighten the black (negative) cable last.
Route the BROWN harness ground wires A and BLACK main battery ground cable B as shown in the image. Both are routed up and over the rubber strap. If the ground wires/cable are routed down the side of the battery, they may interfere with the rear side panel tab. Note the routing of the RED (positive) battery cable C and that the right fender D is pulled away from the chassis. Item E is the constant power fuse connector.
Verify that cables are properly routed.
Secure the right fender using the plastic rivet.
Reinstall the console using the two plastic rivets.
Reinstall the side panel.
It is important to identify what type of battery is installed in the vehicle. Different types of batteries require different service procedures. Proper servicing and upkeep of the battery is very important for maintaining long battery life.
The types of batteries are:
Lead Acid Conventional
Dry Shipped Absorbed Glass Mat (AGM)
Lead Acid Low Maintenance
AGM Low Maintenance
Refer to the examples below to identify the type of battery in your vehicle.
The battery is NOT activated when packaged
A removable cap plugs / strip is located on top of the battery
Distilled water is added as required (Lead Acid only)
A vent tube is located on the side of battery (Lead Acid only)
The battery is activated when packaged
Non removable cap(s) is / are located on top of the battery
Distilled water or electrolyte is NEVER added
To ensure your battery maintains its level of charge, the battery should be connected to a battery trickle charger using the battery charge port 1.
Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher.
If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 or greater using the battery charge port 1.
|
State of Charge |
Voltage |
Action |
Charge Time* |
|
100% |
12.8-13.0 volts |
None, check at 3 mos. from date of manufacture |
None required |
|
75%-100% |
12.5-12.8 volts |
May need slight charge, if no charge given, check in 3 months |
3-6 hours |
|
50%-75% |
12.0-12.5 volts |
Needs charge |
5-11 hours |
|
25%-50% |
11.5-12.0 volts |
Needs charge |
At least 13 hours, verify state of charge |
|
0%-25% |
11.5 volts or less |
Needs charge with desulfating charger |
At least 20 hours |
|
*Using constant current charge @ standard amps specified on top of battery. |
|||
Some models are equipped with a battery. The battery provides power for only two purposes:
Engaging the electric starter motor to start the engine
Powering the Polaris Interactive Digital Display (PIDD) with the ignition key when the engine is off
The engine management system turns on the battery charge relay and charges the battery only when the following conditions are met:
The load shed relay is turned on by the engine management system
Engine speed exceeds 2500 RPM
Chassis DC voltage exceeds 13 volts
If the battery is stored during the winter months, electrolyte will freeze at higher temperatures as the battery discharges. The chart below indicates freezing points by specific gravity.
| Specific Gravity of Electrolyte | Freezing Point |
|---|---|
| 1.265 | -75° F |
| 1.225 | -35° F |
| 1.200 | -17° F |
| 1.150 | +5° F |
| 1.100 | +18° F |
| 1.050 | +27° F |
Recharge the battery to its full capacity every 30 to 60 days.
If the battery is stored or used in a partially charged condition, hard crystal sulfation will form on the plates, reducing the efficiency and service life of the battery.
NEVER add electrolyte to the battery once the battery is in service.
If necessary, only add distilled water to the battery .
Store the battery in the vehicle with the cables disconnected, or store the battery in a cool / dry location. Batteries will self discharge more rapidly when stored in extreme temperatures.
NEVER add electrolyte or distilled water to the battery once the battery is in service.
If you do not drive the vehicle for more than TWO weeks, maintain the Absorbent Glass Mat (AGM) battery with the BatteryMINDer® 2012 AGM - 2 AMP charger (or a similar charger).
BatteryMINDer® 2012 AGM - 2 AMP battery charger
2830438
If you plan to store the vehicle for ONE month or longer, remove the battery from the vehicle and store the battery in a cool / dry location. Continue to maintain the battery with the 2 AMP charger and inspect the battery every 60 days.
Recharge the battery to its full capacity every 30 to 60 days.
If the battery is stored or used in a partially charged condition, hard crystal sulfation will form on the plates, reducing the efficiency and service life of the battery.
NEVER add electrolyte or distilled water to the battery. Doing so will damage the case and shorten the life of the battery.
Store the battery in the vehicle with the cables disconnected, or store the battery in a cool / dry location. Batteries will self discharge more rapidly when stored in extreme temperatures.
NEVER add electrolyte or distilled water to the battery. Doing so will damage the case and shorten the life of the battery.
If you do not drive the vehicle for more than TWO weeks, maintain the Absorbent Glass Mat (AGM) battery with the BatteryMINDer® 2012 AGM - 2 AMP charger (or a similar charger).
BatteryMINDer® 2012 AGM - 2 AMP battery charger
2830438
If you plan to store the vehicle for ONE month or longer, remove the battery from the vehicle and store the battery in a cool / dry location. Continue to maintain the battery with the BatteryMINDer® 2012 AGM - 2 AMP charger (or a similar charger) and inspect the battery every 60 days.
Whenever the snowmobile is transported:
Be sure the fuel cap and oil cap are installed correctly.
Tie the snowmobile to the transporting unit securely using suitable straps.
Remove the ignition key to prevent loss.
As the riding season draws to a close, Polaris recommends riders begin treating their snowmobile’s fuel system with Polaris Carbon Clean or similar commercially-available fuel stabilizer.
Treating the fuel system with Carbon Clean during the last few
rides of the season ensures the entire fuel system is treated. Then,
when it comes time to store the snowmobile, all the rider has to do
is completely fill the fuel tank with fresh, non-oxygenated fuel and
treat the new fuel with Carbon Clean.
It is also recommended
riders use non-oxygenated fuel during the last rides of the season
as non-oxygenated fuel stores better than oxygenated fuel and resists
water vapor absorption.
If the rider was unable to
treat the fuel system and/or use non-oxygenated fuel at the end of
the riding season, the rider should do the following:
The rider should consume as much fuel in the fuel tank as possible during the last rides of the season.
When performing the summerization storage procedures, fill the fuel tank completely with non-oxygenated fuel. Note that most oxygenated fuels contain ethanol. Since ethanol is hydroscopic, oxygenated fuel will absorb a small amount of water vapor during the storage season and more so in humid locations. Completely filling the tank with non-oxygenated fuel minimizes water vapor absorption during the storage period and limits the amount of air and water vapor that can accumulate in the tank.
Treat the fuel in the fuel tank with the recommend amount of Polaris Carbon Clean. The recommended mixing ratio is outlined on the bottle label.
Position the snowmobile outside in a well-ventilated area.
Start and run the engine for 10-15 minutes to distribute the treated fuel throughout the fuel system.
Fogging the engine with Polaris fogging oil or similar commercial alternative is probably the most important storage step a rider can do to ensure the internal parts of their snowmobile’s engine do not rust and corrode during the storage season.
To fog the engine, do the following:
Remove the spark plugs from the engine.
Liberally spray fogging oil into each spark plug hole. If possible, have an assistant slowly pull on the recoil rope to rotate the engine while spraying the oil into each cylinder.
Loosely install the spark plugs.
Never leave the drive belt installed in the clutches as oxidation may form where the belt contacts the aluminum clutch sheave faces.
To clean the drive and driven clutches, do the following:
Remove the primary and spare drive belt from the snowmobile.
Inspect the drive belt for wear and glazing. Compare the primary belt with the spare belt. Decide if a new belt is needed next season and note the primary belt can now be used as the spare belt next season.
Clean the drive and driven clutch sheaves with Isopropyl Alcohol. Allow the alcohol to air dry. Continue cleaning the sheave faces until all belt residue is removed.
Never leave a battery unattended during the storage season. Snowmobile batteries are small and cannot maintain their charge over the storage season. To ensure your battery maintains its level of charge, the battery should be connected to a battery trickle charger using the battery charge port 1.
While the battery can remain installed on the snowmobile, it is recommended the battery be removed from the snowmobile and stored in a cool, and dry location. Removing the battery from the snowmobile facilitates off-site storage of the snowmobile where electricity may not be available to connect a battery charger. In addition, removing the battery allows access to other maintenance items, such as the chaincase chain tensioner bolt.
Connect a Polaris battery charger or equivalent commercially available charger to the battery.
Inspect the electrical connections and wire harnesses throughout the snowmobile. If damage is found, make a note of the damage so that you and your authorized Polaris dealer can address the concern.
Never leave ‘used’ lubricant in the chaincase during the storage season. Doing so may leave water present in the chaincase which may cause corrosion and rust.
Follow the Owner’s Manual procedures and drain / fill the chaincase with new Polaris SCL (Synthetic Chaincase Lubricant). All Polaris PRO-RIDE, AXYS, and MATRYX snowmobile feature ‘fill-to-spill’ lubricant fill specifications which makes it relatively ‘easy’ to re-fill the chaincase.
Rotate the driven clutch in the direction of forward vehicle travel to move the chain slack to the tensioner-side of the drive system. Lock the parking brake.
Loosen the drive chain adjuster lock nut. Turn the adjuster screw inwards until it can no longer be turned by hand.
At this point, turn the adjuster nut ¼ turn counter clockwise.
Tighten and then torque the jam nut to the specification listed in the Owner’s Manual. Release the parking brake.
Snowmobiles, especially those transported on sled decks and open trailers can accumulate a lot of water and road dirt / salt during the riding season. The snowmobile must be thoroughly washed and cleaned to prevent corrosion and rust formation.
Cleaning any Polaris snowmobile should ONLY be done with a mild soap and water solution. Any cleaning, buffing or waxing products containing colorant dye should be avoided. If using products with colorant dye in them, test on an inconspicuous area of the bodywork before applying, as a dye may stain the finish.
Wash the snowmobile with mild soap and water. Note that if a pressure washer is used, care should be taken to not point the pressure washer nozzle close to the snowmobile, which may force high pressure water into suspension / shock shaft seals and exposed electrical connectors.
Dry the snowmobile with a lint-free towel. Allow the entire snowmobile to air dry afterwards.
Clean the engine compartment. Use a shop vacuum if required to remove dirt, leaves, cat tails, etc. from within the engine compartment.
If choosing to apply a cleaner, wax or polish, make sure it does not contain a colorant dye and/or test on an inconspicuous area of the panel. Also make sure the product is safe to use on Molded Nylon 6 material with or without a painted finish.
Hand wash the exhaust system and dry the pipe and silencer with a clean shop towel.
Apply “spray” metal protectant on exposed metal components, such as the exhaust pipe, silencer, shock shafts, and suspension springs / pivots.
After washing the snowmobile, it is important to use Polaris Premium All Season grease to lubricate the various suspension / steering pivot points. Doing so forces any water accumulated within the joints out which prevents the formation of corrosion and rust.
Use a grease gun and Polaris Premium All Season Grease. Reference the appropriate Owner’s Manual to locate any / all grease zerks on the steering and suspension systems.
Pump fresh grease into all zerks until the grease can be seen purging out of each joint.
Use a paper towel to clean up and remove all of the residual purged grease from the joints.
Never store the snowmobile in a hot, humid location if possible. Try to store the snowmobile away from direct sunlight.
Cover the snowmobile with a Polaris cover or after-market equivalent cover.
Store in a location away from water, tall grass, and direct sunlight. The storage location should have some level of ventilation to prevent stagnant, humid air from accumulating in and around the snowmobile.
Preparing a snowmobile for in-season service is basically performing some of the summer storage procedures in reverse order.
Move the snowmobile outside to a well-ventilated area. Raise the rear suspension up, off the ground. Remove the engine compartment side panel and hood.
Prep the primary and back up (secondary) for winter use. It is recommended the belts be washed with a solution of warm, soapy water and allowed to air dry.
If the snowmobile is equipped with electric start or a PIDD on-board battery, remove the battery from the battery charger and re-install it back into the battery box. Follow the owner’s manual for battery installation procedures.
Verify the spark plugs are installed and torqued. Re-install the spark plug wires.
If you placed dryer sheets inside the engine compartment, remove them.
Using clean and dry shop towel, wipe down the exhaust pipe , silencer, and clutch sheaves.
Install the primary drive belt onto the clutches with the “Polaris” writing readable from the outside of the snowmobile.
Install the back-up (secondary) drive belt into the belt holder.
On the carbureted snowmobiles, turn the fuel shut-off valve to the ON position.
With the track suspended up, off the ground, follow the track tension adjustment procedure as outlined in your owner’s manual.
Start and run the engine. Allow the engine to run for at least 15 minutes. Occasionally “blip” the throttle to rev the engine.
While the engine is running, verify there are no coolant leaks (on liquid cooled engines). After engaging the throttle a few times to spin the track, verify the track is aligned with the slide rails.
Turn off the engine. If the track requires, re-align the track at this time.
After adjusting the track or allowing the engine to cool down. Add coolant to reservoir bottle if required.
Re-start the engine and allow it to run for another 15 minutes. After 15 Minutes, shutoff the engine and allow the exhaust pipe to cool.
Remove and discard the spark plugs. Install new spark plugs into the engine. Obtain two more new spark plugs and install them into the spark plug holders or storage bag.
Inspect the ski wear bars/carbides. Now is the time to replace the wear bars if damage if found or carbides are worn.
Add Carbon Clean to the fuel tank.
Log onto www.ridecommand.com and download the latest TRAILS PIDD update files. Update the PIDD (if equipped) with the latest TRAILS update file.
Grease the rear suspension grease zerks with Polaris Premium All Season grease just enough to push out any water that may have accumulated in the suspension pivot points.
|
Capacities and Dimensions |
|
|
Body Style |
AXYS |
|
Rider Capacity |
1 |
|
Coolant Capacity |
4 qt (3.8 l) |
|
Chaincase Oil Capacity |
10 oz (296 ml) |
|
Fuel Tank Capacity |
12 gal (45.4 l) |
|
Gearcase Oil Capacity |
N/A |
|
Oil Capacity (qts./l) |
3.9 qt (3.7 l) |
|
Height |
46 in (116.8 cm) |
|
Length |
117 in (297.2 cm) |
|
Designed Width |
47 in (119.4 cm) |
|
Brake Type |
AXYS Radial |
|
Drive Clutch Center Distance |
10.625 in (27 cm) |
|
Drive Belt P/N |
3211165 |
|
Drive Clutch |
P-85 |
|
Driven Clutch |
Lightweight Team Roller Reverse |
|
Reverse Transmission |
Electronic Reverse |
|
Engine and Cooling |
|
|
Engine Part Number |
1208646 |
|
Engine |
ASM ENG S8646-6044-LL6P |
|
Displacement |
599 cc |
|
Cylinders |
2 |
|
Bore x Stroke (mm) |
77.25 x 64 |
|
Alternator Output |
400 watt |
|
Throttle Body |
1204920 |
|
Recommended Engine Oil |
VES |
|
Throttle Body Bore Size |
(46 mm) |
|
Idle RPM |
1700 +/- 200 |
|
Rated Operating RPM |
8250 +0/- 250 |
|
Cooling |
Liquid |
|
Ignition Type |
CDI |
|
Ignition Timing °BTDC |
18° @ idle, 1700 RPM w/120°F (49°C) water temp |
|
Spark Plug / Gap |
NGK® BPR9ES / 0.70 in (0.027 mm) |
|
Recommended Fuel Octane |
91 recommended (87 minimum) |
| Clutch Settings | |||||
|---|---|---|---|---|---|
| ALTITUDE meters (feet) |
DRIVE CLUTCH | DRIVEN CLUTCH | |||
| Shift Weight | Clutch Spring (Electric Start) |
Clutch Spring | Driven Helix | Chaincase Gearing / Pitch |
|
| 0-600 (0-2000) |
10-64 (1321585) |
Black 140/330 (7043829) |
Black/Purple 160/240 (7043363) |
48/42/.36 BA35 (5140312) |
22/41/70P
1.25 RIP II |
| 600-1200 (2000-4000) |
10-62 (1321586) |
||||
| 1200-1800 (4000-6000) |
10-60 (1321587) |
||||
| 1800-2400 (6000-8000) |
10-58 (1321588) |
||||
| 2400-3000 (8000-10,000) |
10-56 (1321684) |
||||
| 3000-3600 (10,000-12,000) |
10 AL (1321531) |
||||
| Drive Clutch Bolt Torque: 80 ft-lbs
(108Nm) Re-torque after running engine. *Use 2 gram lighter shift weights when operating in temperatures above 40° F (5° C). |
|||||
|
Capacities and Dimensions |
|
|
Body Style |
AXYS |
|
Rider Capacity |
1 |
|
Coolant Capacity |
4 qt (3.8 l) |
|
Chaincase Oil Capacity |
10 oz (296 ml) |
|
Fuel Tank Capacity |
12 gal (45.4 l) |
|
Gearcase Oil Capacity |
N/A |
|
Oil Capacity (qts./l) |
3.9 qt (3.7 l) |
|
Height |
48.5 in (123.2 cm) |
|
Length |
125 in (317.5 cm) |
|
Designed Width |
46.5 in (118 cm) |
|
Brake Type |
Hayes® Phantom |
|
Drive Clutch Center Distance |
10.625 in (27 cm) |
|
Drive Belt P/N |
3211165 |
|
Drive Clutch |
P-85 |
|
Driven Clutch |
Lightweight Team Roller Reverse |
|
Reverse Transmission |
Electronic Reverse |
|
Engine and Cooling |
|
|
Engine |
ASM-ENG S6202-6044-LO6P |
|
Displacement |
599 cc |
|
Cylinders |
2 |
|
Bore x Stroke (mm) |
77.25 x 64 |
|
Alternator Output |
400 watt |
|
Throttle Body |
1204920 |
|
Recommended Engine Oil |
VES |
|
Throttle Body Bore Size |
46 mm |
|
Idle RPM |
1700 +/- 200 |
|
Rated Operating RPM |
8250 +0/- 250 |
|
Cooling |
Liquid |
|
Ignition Type |
CDI |
|
Ignition Timing °BTDC |
18° @ idle, 1700 RPM w/120°F (49°C) water temp |
|
Spark Plug / Gap |
NGK® BPR9ES / .70 inches (.027 mm) |
|
Recommended Fuel Octane |
91 recommended (87 minimum) |
| Clutch Settings | |||||
|---|---|---|---|---|---|
| ALTITUDE meters (feet) |
DRIVE CLUTCH | DRIVEN CLUTCH | |||
| Shift Weight | Clutch Spring | Clutch Spring | Driven Helix | Gearing (U : L -Pitch) |
|
|
* Shaded cells indicate factory settings. Use 2
gram lighter shift weights when operating in temperatures above 40°
F (5° C).
Drive Clutch Bolt Torque: 80 ft-lbs (108 Nm) Re-torque after running engine. |
|||||
| 0-450 (0-1500) | 10-64 (1321585) | 140/330 (7043829) |
BLK/PURPLE (7043363) |
STR 40 LW (5143880) |
19:40–68P |
| 450-900 (1500-3000) | 10-62 (1321586) | ||||
| 900-1500 (3000-5000) | 10-60 (1321587) | ||||
| 1500-2100 (5000-7000) | 10-58 (1321588) | ||||
| 2100-2700 (70000-9,000) | 10-56 (1321684) | ||||
| 2700-3350 (9000-11,000) | 10-54 (1321685) | ||||
| Diagnostic Trouble Codes (DTCs) – AXYS | |||||
|---|---|---|---|---|---|
| SPN = Suspect Parameter
Number / FMI = Failure Mode Indicator MIL Status: ON = Check Engine LED Illuminated |
|||||
| Trouble Code | SPN | FMI | P-CODE | MIL STATUS | Condition |
| Throttle Position Sensor 1 | 51 | 3 | P0123 | ON | This Trouble Code sets if the Throttle Position
Sensor Signal is above 4.39 Volts. Can be caused by Damaged Wiring, a faulty Throttle Position Sensor or ECU / Connections. |
| 4 | P0122 | This Trouble Code sets if the Throttle Position
Sensor Signal is below 0.7 Volts. Can be caused by Damaged Wiring, a faulty Throttle Position Sensor or ECU / Connections. |
|||
| 10 | P0120 | This Trouble Code sets when the Throttle Position Sensor Signal changes too rapidly to be correct. The condition can be caused by intermittent connections causing the TPS voltage to jump around between readings. Check for damaged connectors or wiring. | |||
| Vehicle Speed Signal | 84 | 2 | P0503 | This Trouble Code Sets if the Vehicle Speed
Signal is intermittent or missing. Can be caused by Damaged Wiring/Connections or a Faulty / Loose Vehicle Speed Sensor |
|
| Engine Oil Level Sensor / Switch | 98 | 17 | P250F | OFF | This Trouble Code Sets if the Oil Level is Too
Low. Can be caused by Low Oil Level, a faulty Oil Level Sensor or Faulty ECU / Connections. |
| Intake Air Temperature Sensor | 105 | 3 | P0113 | ON | This Trouble Code sets if the Intake Air Temperature
Sensor Signal is above 4.9 Volts. Can be caused by Damaged Wiring, a faulty Intake Air Temperature Sensor or ECU / Connections. |
| 4 | P0112 | This Trouble Code sets if the Intake Air Temperature
Sensor Signal is below 0.19 Volts. Can be caused by Damaged Wiring, a faulty Intake Air Temperature Sensor or ECU / Connections. |
|||
| 10 | P0114 | Abnormal Rate of Change. | |||
| Barometric Pressure Sensor | 108 | 3 | P2229 | ON | This Trouble Code Sets if the Barometric Pressure
Sensor Signal Circuit is Open or Shorted to Battery Voltage. Can be caused by Damaged Wiring / Connections, a Faulty Ambient Pressure Sensor or ECU |
| 4 | P2228 | This Trouble Code Sets if the Barometric Pressure
Sensor Signal Circuit is Shorted to Ground. Can be caused by Damaged Wiring / Connections, a Faulty Ambient Pressure Sensor or ECU |
|||
| 10 | P2230 | This Trouble Code sets if the Barometric Pressure
Sensor Signal indicates an Unrealistic Rate of Change. Can be caused by Damaged Wiring, a faulty Barometric Pressure Sensor or ECU / Connections. |
|||
| Engine Temperature Sensor | 110 | 3 | P0118 | ON | This Trouble Code sets if the Engine Coolant
Temperature Sensor Signal is above 4.8 Volts. Can be caused by Damaged Wiring, a faulty Coolant Temperature Sensor or ECU / Connections. |
| 4 | P0117 | This Trouble Code sets if the Engine Coolant
Temperature Sensor Signal is below 0.1 Volts. Can be caused by Damaged Wiring, a faulty Coolant Temperature Sensor or ECU / Connections. |
|||
| 0 | P1217 | OFF | This Trouble Code sets if the Engine Temperature
indicates a Critical Over Temperature Condition and the engine is
running in a limp-home mode to prevent damage. Can be caused by any failure that would cause the engine to overheat. |
||
| 16 | P0217 | This Trouble Code sets if the Engine Temperature
indicates a Severe Over Temperature Condition. Can be caused by any failure that would cause the engine to overheat. This Trouble Code Does Not indicate a problem with the Engine Temperature Sensor. |
|||
| 15 | P1116 | This Trouble Code sets if the Engine Temperature
indicates an Over Temperature Condition. Can be caused by any failure that would cause the engine to overheat. This Trouble Code Does Not indicate a problem with the Engine Temperature Sensor. |
|||
| DC Chassis Voltage | 167 | 3 | P1569 | ON | This Trouble Code sets if the System Voltage
is above an acceptable level. Can be caused by Damaged Wiring, a Faulty Voltage Regulator or Faulty ECU. |
| 4 | P1568 | This Trouble Code sets if the System Voltage
is below an acceptable level. Can be caused by Damaged Wiring, a faulty stator, Faulty Voltage Regulator or Faulty ECU. |
|||
| Exhaust Temperature Sensor | 173 | 3 | P0546 | ON | This Trouble Code sets if the engine has been
running above 3000 RPM for more than 2 minutes and the Exhaust Temperature
Sensor Signal is above 4.90 Volts. Can be caused by Damaged Wiring, a faulty Engine Temperature Sensor or ECU / Connections. |
| 4 | P0545 | This Trouble Code sets if the engine has been
running above 3000 RPM for more than 2 minutes and the Exhaust Temperature
Sensor Signal is below 0.06 Volts. Can be caused by Damaged Wiring, a faulty Engine Temperature Sensor or ECU / Connections. |
|||
| 0 | P1517 | This Trouble Code Sets if the Engine was Shut
Down due to High Exhaust Temperature. Can be caused by a Faulty Exhaust Temperature Sensor / Connections or Lean Air / Fuel Ratio causing high exhaust temperature. |
|||
| 10 | P1546 | Abnormal rate of change. | |||
| ECU Memory Checksum Error | 628 | 13 | P0601 | OFF | This Trouble Code Sets if an Internal Memory
Fault is detected in the Engine Controller Can only be caused by a defective ECU. |
| Crankshaft Sensor Signal Fault | 636 | 2 | P0335 | OFF | This Trouble Code sets if the Engine is Running
and No Signal is Detected from the 5X Crankshaft Sensor. Can be caused by Damaged Wiring, a faulty Crankshaft Sensor or ECU / Connections. |
| Crankshaft Position Sensor Circuit Fault | 636 | 8 | P0336 | OFF | This Trouble Code sets if the Engine is Running
and the number of pulses from the 5X Crankshaft Sensor is not correct. Can be caused by Damaged Wiring, a faulty Crankshaft Sensor or ECU / Connections. |
| Fuel Injector (MAG) | 651 | 5 | P0261 | ON | This Trouble Code sets if an Open Circuit Condition
is detected in the MAG Cylinder Port Injector Control Circuit. Can be caused by Damaged Wiring, a faulty Fuel Injector or ECU / Connections. |
| 3 | P0262 | This Trouble Code sets if a Short to Voltage
is detected in the MAG Cylinder Port Injector Control Circuit. Can be caused by Damaged Wiring, a faulty Fuel Injector or ECU / Connections. |
|||
| Fuel Injector (PTO) | 652 | 5 | P0264 | ON | This Trouble Code sets if an Open Circuit Condition
is detected in the PTO Cylinder Port Injector Control Circuit. Can be caused by Damaged Wiring, a faulty Fuel Injector or ECU / Connections. |
| 3 | P0265 | This Trouble Code sets if a Short to Voltage
is detected in the PTO Cylinder Port Injector Control Circuit. Can be caused by Damaged Wiring, a faulty Fuel Injector or ECU / Connections. |
|||
| Knock Sensor | 731 | 4 | P0327 | ON | This Trouble Code sets if the Engine Speed is
above 6000 RPM and the Detonation Sensor Signal is below 1.23 Volts
for more than 2 seconds. Can be caused by Damaged Wiring, a faulty Detonation Sensor or ECU / Connections. |
| 2 | P0325 | This Trouble Code Sets if the Knock Sensor Signal
indicates an Unrealistic Value. Can be caused by a Faulty Knock Sensor / Connections, a Loose Sensor or Excessive Engine Mechanical Noise. |
|||
| Ignition Coil Primary Driver (MAG) | 1268 | 5 | P1351 | ON | This Trouble Code Sets if the Ignition Coil
Driver Circuit is Open. Can be caused by Damaged Wiring / Connections, a Ignition Coil or ECU |
| Fuel Pump Driver Circuit | 1347 | 5 | P0230 | ON | This Trouble Code Sets if the Fuel Pump Relay
Driver Circuit is Open. Can be caused by Damaged Wiring / Connections, a Faulty Fuel Pump or ECU. |
| Knock (DET) Level (MAG) | 1352 | 0 | P1336 | ON | This Trouble Code Sets if the Engine Controller Reaches the Maximum Detonation Control Limit by Fuel Correction on the Mag Cylinder |
| 16 | P2336 | This Trouble Code Sets if Cylinder 1 (MAG) Knock Sensor reaches a Critical Level. Can be caused by Excessive Knock (Fuel Problems), a Lean Running Condition or Engine Mechanical Problems. | |||
| Knock (DET) Level (PTO) | 1353 | 0 | P1337 | ON | This Trouble Code Sets if the Engine Controller Reaches the Maximum Detonation Control Limit by Fuel Correction on the PTO Cylinder. |
| 16 | P2337 | This Trouble Code Sets if Cylinder 2 (PTO) Knock Sensor reaches a Critical Level. Can be caused by Excessive Knock (Fuel Problems), a Lean Running Condition or Engine Mechanical Problems. | |||
| Sensor Supply Voltage 1 (TPS / TMAP) |
3509 | 4 | P06B1 | ON | This Trouble Code sets if the Sensor Supply 1 Voltage is below an acceptable limit (4.50 Volts). Can be caused by Damaged Wiring or Faulty / Shorted Sensors. |
| Sensor Supply Voltage 2 (Speed Sensor) |
3510 | 4 | P06B4 | OFF | This Trouble Code sets if the Sensor Supply 2 Voltage is below an acceptable limit (4.50 Volts). Can be caused by Damaged Wiring or Faulty / Shorted Sensors. |
| Electronic Oil Pump | 3589 | 5 | P16BA | ON | This Trouble Code Sets if the Oil Pump Driver
Circuit is Open. Can be caused by Damaged Wiring / Connections, a Faulty Oil Pump/Connections or Faulty ECU / Connections. |
| 12 | P16BC | This Trouble Code Sets if a Failure is Detected
in the Oil Pump Driver Circuit. Can be caused by Damaged Wiring / Connections, a Faulty Oil Pump/Connections or Faulty ECU / Connections. |
|||
| ECU Output Supply Voltage Fuel Injector Power (16V) |
3598 | 3 | P16A9 | ON | This Trouble Code sets if the Injector Output Supply 2 Voltage is above an acceptable limit. Can be caused by Damaged Wiring or Faulty / Shorted Connectors. |
| 4 | P16A8 | This Trouble Code sets if the Injector Output Supply 2 Voltage is below an acceptable limit. Can be caused by Damaged Wiring or Faulty / Shorted Connectors. | |||
| ECU Output Supply Voltage Ground Speed Sensor (5V) |
3599 | 3 | P17AA | ON | This Trouble Code Sets if the ECU Output Supply Voltage #3 (Vehicle Speed Sensor Supply) is Too High. Can be caused by Damaged Wiring / Connections, a Faulty Vehicle Speed Sensor / Connections or Faulty ECU / Connections. |
| 4 | P17AB | This Trouble Code Sets if the ECU Output Supply Voltage #3 (Vehicle Speed Sensor Supply) is Too Low. Can be caused by Damaged Wiring / Connections, a Faulty Vehicle Speed Sensor / Connections or Faulty ECU /Connections. | |||
| Throttle Release Signal | 520194 | 3 | P1555 | ON | This Trouble Code Sets if the Throttle Release Switch Signal is Open Circuit or Shorted to Battery Voltage. Can be caused by Damaged Wiring / Connections, a Faulty Throttle Safety Switch or ECU. |
| 4 | P1554 | This Trouble Code Sets if the Throttle Safety Switch Signal is Shorted to Ground. Can be caused by Damaged Wiring / Connections, a Faulty Throttle Safety Switch or ECU. | |||
| 7 | P1552 | This Trouble Code Sets if the Throttle Release Switch Signal Indicates a Throttle Stuck Open. Can be caused by a Stuck Throttle or Mis-adjusted / Stuck Throttle Linkage. | |||
| Exhaust Valve Solenoid | 520215 | 5 | P1477 | ON | This Trouble Code sets if an Short to Voltage Condition is detected in the Exhaust Valve Solenoid Control Circuit. Can be caused by Damaged Wiring, a faulty Exhaust Valve Solenoid or ECU / Connections. |
| 3 | P1479 | This Trouble Code sets if an Short to Voltage Condition is detected in the Exhaust Valve Solenoid Control Circuit. Can be caused by Damaged Wiring, a faulty Exhaust Valve Solenoid or ECU / Connections. | |||
| Load Shed Relay | 520219 | 5 | P1646 | ON | This Trouble Code Sets if the Load Shed Relay Driver Circuit is Open. Can be caused by Damaged Wiring / Connections, a Accessory Ignition Relay or ECU. |
| 3 | P1647 | This Trouble Code Sets if the Load Shed Relay Driver Circuit is Shorted to Voltage. Can be caused by Damaged Wiring / Connections, a Faulty Accessory Relay or ECU. | |||
| Battery Charge Relay Battery-Equipped Models Only |
520220 | 5 | P163C | ON | This Trouble Code Sets if the Charge Relay Driver Circuit is Open. Can be caused by Damaged Wiring / Connections, a Charge Relay or ECU. |
| 3 | P163D | This Trouble Code Sets if the Charge Relay Driver Circuit is Shorted to Voltage. Can be caused by Damaged Wiring / Connections, a Faulty Charge Relay or ECU. | |||
| Oil Pump or Fuel Injector Settings Not Programmed | 520241 | 13 | P1278 | ON | This Trouble Code Sets if Either the Fuel Injector
or Oil Injection Pump Calibration has Not Been Programmed. Update
the Injector/Oil Pump Settings. WARNING: Do Not Operate the Vehicle with This Trouble Code Set. |
| Ground Speed Pulses per Mile Not Programmed | 520242 | 13 | P1279 | ON | This Trouble Code Sets if the Vehicle Speed Sensor Setting is Not Properly Programmed in the ECU. Reflash ECU. |
| EV Actuator / Gauge Relay | 520328 | 5 | P140D | ON | For all E-VES Diagnostic Trouble Codes (DTCs), see: E-VES Diagnostic Trouble Codes (DTCs) |
| 3 | P140E | ||||
| Riding With Brakes on Moderately Severe | 520555 | 31 | C2418 | ON | Brakes are applied too long above certain engine rpm. |
| Riding With Brakes on Most Severe | 520556 | C2419 | |||
| E-VES Diagnostic Trouble Codes (DTCs) | ||||||
|---|---|---|---|---|---|---|
| SPN = Suspect Parameter Number / FMI = Failure Mode Indicator | ||||||
| P-CODE | SPN | FMI | Description | Likely Cause(s) | ECU Response | Primary Course of Action |
| P1400 | 520324 | 3 | Diagnostic voltage too high | Diagnostic line (Pink / Black in harness, Brown
on signal converter) short to +12V Actuator power (Red / Black) removed |
ECU will not allow UP state. Fuel according to actual position |
Inspect PWM converter wiring for
chaffing / broken wires Ensure no loose pins in converter connector Replace signal converter if no wire / connector issues are found |
| P1401 | 5 | Diagnostic circuit open / grounded | Diagnostic line (Pink / Black in harness, Brown
on signal converter) open circuit Command wire (Dark Blue / White) short to GND Command wire (Dark Blue / White) open Actuator power (Red / Black) removed |
|||
| P1402 | 13 | Learn failure | Feedback voltage out of range during learn | ECU will force to DOWN state and fuel accordingly | Ensure battery is sufficient for relearn (maintains
11.5 volts during the entire procedure) Ensure Signal converter and / or actuator are not disconnected Ensure EV relay is connected, operational (clicks) and has no damage to terminal wiring Check for broken EV cable Perform cable measurement test per service manual Remove and inspect the valve assembly for causes for too little or too much travel. |
|
| P1403 | 12 | Hardware fault | Actuator position sensor failed Voltage too high during EV learn |
Replace EV Actuator | ||
| P1404 | 7 | Position not achieved | Actuator does not reach commanded state Will also trigger one of the following: P140A / B / C |
Fuel according to actual valve position | See actions for P140A / B / C | |
| P1405 | 2 | PWM set missing | Command wire (Dark Blue / White) to actuator
open circuit Command wire (Dark Blue / White) short to GND |
All valve positions allowed, Fuel according to actual position, When signal is returned, actuator will re-initialize | Inspect signal converter wiring
for chaffing or broken wires Ensure no loose pins on converter connector Replace signal converter if no wire / connector issues are found |
|
| P1406 | 520335 | 3 | Feedback position short to +12V | Feedback position (Dark Blue / Yellow on harness,
Grey on signal converter) short to +12V Actuator power (Red / Black) removed |
ECU will force to DOWN state and fuel accordingly | |
| P1407 | 5 | Feedback position circuit open / grounded | Feedback position (Dark Blue/Yellow on harness,
Grey on signal converter) short to GND Feedback position (Dark Blue/Yellow on harness, Grey on signal converter) open Actuator power (Red / Black) removed |
|||
| P1408 | 10 | Abnormal rate of change | Actuator achieves valve state too fast or resistance
too low Actuator power (Red / Black) removed Command wire (Dark Blue / White) short to +12V Command wire (Dark Blue / White) short to GND |
Position forced to last known state, fuel according to last known state | Inspect EV cable for damage or loose attachment at valve assembly | |
| P1409 | 520334 | 31 | Actuator overheat | Actuator Circuit board too hot Internal short circuit |
ECU will not allow UP state, Fuel worst case valve UP state | Replace EV Actuator |
| P1410 | 520337 | 31 | Learn default position | Actuator / Signal converter power (Red / Black) removed | ECU will not allow UP operation | Inspect Signal converter wiring
for chaffing or broken wires Ensure no loose pins on converter connector Check actuator wiring for broken wires, loose pins on actuator connector Replace signal converter |
| P140A | 520325 | 31 | Valve OPEN position not achieved | Valve UP position voltage out of range | Fuel according to actual valve position | Measure cable travel length Verify smooth valve operation by operating the cable by hand through its full travel Perform EV relearn procedure Remove E-VES assembly and inspect for heavy carbon build-up and / or damage |
| P140B | 520326 | 31 | Valve MID position not achieved | Valve MID position voltage out of range | ||
| P140C | 520327 | 31 | Valve DOWN position not achieved | Valve DOWN position voltage out of range | If occasional, this fault is nothing to be concerned
about If persistent: Measure cable travel length Verify smooth valve operation by operating the cable by hand through its full travel Perform EV relearn procedure Remove E-VES assembly and inspect for heavy carbon build-up and / or damage |
|
| P140D | 520328 | 5 | EV relay circuit open / grounded | EV relay supply power line is open | ECU will force to DOWN state and fuel accordingly | Inspect EV relay for corrosion
or loose terminals Replace EV relay |
| P140E | 3 | EV relay short to power | EV relay Grey / Yellow wire short to Power | |||
Unless you have experience and training in two-cycle engine repair, your dealer can assist if technical problems arise.
|
Problem |
Probable Cause |
Solution |
|---|---|---|
|
Erratic engine operating RPM during acceleration or load variations |
Drive clutch binding |
Your dealer can perform this service. |
|
Driven clutch malfunction |
Your dealer can perform this service |
|
|
Harsh drive clutch engagement |
Drive belt worn or too narrow |
Replace the drive belt. |
|
Excessive belt/sheave clearance |
Your dealer can perform this service. |
|
|
Drive belt turns over |
Wrong belt for application |
Replace the drive belt. |
|
Clutch alignment out of spec |
Your dealer can perform this service. |
|
|
Engine mount broken or loose |
Inspect and replace. |
|
|
Machine fails to move |
Clutch jammed |
Check for twisted belt or broken spring. Your dealer can perform this service. |
|
Track jammed |
|
|
|
Chaincase sprocket or chain jammed or broken |
Chain is loose or broken or chain tightener is loose. Your dealer can perform this service. |
|
|
Noise in drive system |
Broken drive clutch components |
Your dealer can perform this service. |
|
Bearing failure/ chaincase, jackshaft, or front drive shaft |
Your dealer can perform this service. |
|
|
Drive belt surface flat spots |
Inspect and replace as needed. |
|
|
Drive chain loose |
Inspect and adjust (or replace). |
|
|
Drive chain worn, sprocket teeth broken |
Your dealer can perform this service. |
|
|
Poor low RPM performance |
Worn drive belt |
Inspect and replace as needed. |
|
Excessive belt/sheave clearance |
Your dealer can perform this service. |
|
|
Sticky clutch |
Your dealer can perform this service. |
|
|
Poor fuel quality |
Use 87-91 octane fuel (or higher). |
|
|
Engine doesn't turn |
Seized engine |
Your dealer can perform this service. Seizure is a result of poor lubrication, inadequate fuel supply, broken parts or improper cooling. |
|
Hydrostatic lock |
Fuel may have entered the crankcase while the vehicle was standing or being transported. Drain plug(s) are located on the lower crankcase for emergency draining. Your dealer can perform this service |
|
|
Engine turns but fails to start |
Faulty ignition |
Install new spark plug(s). If engine still fails to start, check for spark. If there's no spark, Your dealer can perform this service. |
|
No fuel to engine |
|
|
|
Poor engine compression |
This indicates a major engine problem that must be repaired before operating. Your dealer can perform this service. |
|
|
Engine lacks power |
Fouled or defective spark plug(s) |
Replace the plug(s). |
|
Fuel filter (loss of high RPM power) |
Your dealer can perform this service. |
|
|
Plugged fuel filter or tank pick-up sock |
Your dealer can perform this service. |
|
|
Incorrect clutching |
Your dealer can perform this service. |
|
|
Engine continually backfires |
Faulty plug(s) |
Change plug(s), ensure caps are seated. |
|
Fuel System |
Dirt or ice may be in the fuel system (deicer should be added to non-ethanol fuel at all times for assurance against fuel line icing). |
|
|
Incorrect throttle freeplay or faulty switch |
Your dealer can perform this service. |
|
|
Engine requires more than normal pulls to start |
Poor fuel |
Replace with fresh winter fuel. |
|
Not enough fuel getting to engine |
Your dealer can perform this service. |
|
|
Plugged fuel filter or tank pick-up sock |
Your dealer can perform this service. |
|
Problem |
Solution |
|---|---|
|
Rear suspension bottoms too easily |
|
|
Rides too stiff in rear |
|
|
Too much weight transfer when climbing |
Refer to the Suspension Quick Set-Up Guide for details. |
|
Too little weight transfer when climbing |
Refer to the Suspension Quick Set-Up Guide for details. |
|
Machine darts from side to side |
|
|
Front end pushes |
|
|
Steering is heavy |
|
| Belt Wear/Burn Diagnosis | |
|---|---|
| Causes | Solutions |
| Driving at low RPM | Drive at higher RPMs. Gear the machine down. Check belt deflection. |
| Insufficient warm-up | Warm the engine at least five minutes. Put the transmission in neutral to warm belt. In extreme cold weather, take the drive belt off the snowmobile and warm it up. Break snowmobile loose from the snow. |
| Towing at low RPM | Do not tow in deep snow. Use fast, aggressive throttle to engage clutch. |
| Riding with high RPM and slow speed (8000 RPM/10 MPH/16 km/h) | Lower the gear ratio. Reduce RPM. Avoid riding in high ambient temperatures. Check for snow ingestion. |
| Ice and snow build-up between track and tunnel | Warm the engine at least five minutes. Take the drive belt 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 | Inspect clutch components. Your dealer can perform this service. |
| Slow, easy clutch engagement | Use fast, aggressive throttle to engage clutch. |
|
Cause of DET Activation |
Solution |
|
Poor quality fuel |
Replace with higher quality fuel |
|
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 |
Your POLARIS dealer can perform service |
|
Alcohol-based fuel additive used with Ethanol fuel |
Do not add deicers or additives that contain any form of alcohol while using up to 10% Ethanol fuel |
|
Improper engine modifications |
Do not modify the engine |
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 Potential (DC Chassis Voltage) |
Voltage Too High |
167 |
3 |
|
Voltage Too Low |
4 |
||
|
Exhaust Temperature Sensor |
Voltage Too High |
173 |
3 |
|
Voltage Too Low |
4 |
||
|
ECU Memory |
Checksum/CRC Error |
628 |
13 |
|
Injector 1 (MAG |
Driver Circuit Open/Grounded |
651 |
5 |
|
Driver Circuit Short to B+ |
3 |
||
|
Injector 2 (PTO) |
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 Correction Limit Reached |
1352 |
0 |
|
Knock Above Critical Level |
16 |
||
|
Knock Level Cylinder 2 (PTO) |
Maximum Detonation Correction Limit Reached |
1353 |
0 |
|
Knock Above Critical Level |
16 |
||
|
Sensor Supply Voltage 1 (TPS/TMAP Sensor Power) |
Voltage Too Low |
3509 |
4 |
|
Sensor Supply Voltage 2 (Ground Speed Sensor) |
Voltage Too Low |
3510 |
4 |
|
ECU Output Supply Voltage 2 (Injection Supply PWR) |
Voltage Too High |
3598 |
3 |
|
Voltage Too Low |
4 |
||
|
Throttle Release Signal |
Voltage Too High |
520194 |
3 |
|
Voltage Too Low |
4 |
||
|
Throttle Stuck |
7 |
||
|
Chassis Relay |
Driver Circuit Open/Grounded |
520208 |
5 |
|
Driver Circuit Short to B+ |
3 |
||
|
Exhaust Valve Solenoid (600 Only) |
Driver Circuit Grounded |
520215 |
5 |
|
Driver Circuit Short to B+ |
3 |
||
|
EV Actuator Driver (Controller) (800 H.O. Only) |
Voltage Too High |
520324 |
3 |
|
Voltage Too Low |
4 |
||
|
Learn Failure |
13 |
||
|
Hardware Failure |
12 |
||
|
Commanded Pos. Not Achieved |
7 |
||
|
PWM Set Missing |
2 |
||
|
MAX Temperature Exceeded |
520334 |
31 |
|
|
Signal Out of Range - Valve Open |
520325 |
31 |
|
|
Signal Out of Range - Valve Mid |
520326 |
31 |
|
|
Signal Out of Range - Valve Closed |
520327 |
31 |
|
|
Short to Battery Voltage |
520335 |
3 |
|
|
Short to Ground |
4 |
||
|
Abnormal Transition |
10 |
||
|
Electronic Oil Pump |
Driver Circuit Open / Grounded |
3589 |
4 |
|
Driver Circuit Grounded |
5 |
||
|
Oil Pump or Fuel Injector Settings not Programmed |
Out of Calibration |
520241 |
13 |
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:
Serial number
Model number
Dealer name
Date of purchase
Details of trouble experienced
Length of time and conditions of operation
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.
United States & Canada: 1-800-POLARIS (1-800-765-2747)
POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a 12 MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
THIS WARRANTY MAY BE VOIDED BY ANY UNAPPROVED MODIFICATIONS TO THIS VEHICLE THAT AFFECT POWERTRAIN, EXHAUST, CHASSIS OR SUSPENSION.
Promotional warranties are sometimes offered by POLARIS, including but not limited to:
Two-year extended engine coverage
Two-year powertrain coverage
Extended service contract
See your dealer for details and separate terms and conditions for any promotional warranties.
At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. 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 your proof of warranty coverage. 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 YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.
This POLARIS Limited Warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed.
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; 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.
This warranty excludes damages or failures caused by abuse, accident, fire or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:
Skis
Tracks
Suspension components
Brake components
Seat components
Clutches and components
Steering components
Batteries
Light bulbs/Sealed beam lamps
Idler wheels
Sealants
Coolant
Fuel
Ski wear rods
Slide rails
Finished and unfinished surfaces
Carburetor/Throttle body components
Engine components
Drive belts
Hydraulic components
Circuit breakers/Fuses
Electronic components
Spark Plugs
Lubricants
Filters
1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil.
2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.
This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS’ OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, 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 OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTAL, INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE 12 MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.
If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. 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 suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.
Warranty or service bulletin repairs must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your product was purchased, warranty and service bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product.
If you are traveling temporarily outside the country where your product was purchased, you should take your product 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 to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Product importation rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS in order to register your product in your new country. You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle.
If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have any questions. This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer’s authorized location. This policy does not apply to safety bulletins.
If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty.
Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries. If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect.
For questions call POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
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. Environmental 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; 4,000 kilometers (2,485 miles) of vehicle travel; or 30 calendar months from the date of purchase, whichever comes first.
This Emissions Limited Warranty covers components if their failure increases the vehicle’s regulated emissions, and it covers components of systems if their only purpose is to control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This Emissions Limited Warranty does not cover components if their failure does not increase the vehicle’s regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to the following systems:
Air-induction system
Fuel system
Ignition system
Exhaust gas recirculation systems
The following parts are also considered emission-related components for exhaust emissions:
Aftertreatment devices
Crankcase ventilation valves
Sensors
Electronic control units
The following parts are considered emission-related components for evaporative emissions:
Fuel Tank
Fuel Cap
Fuel Line
Fuel Line Fittings
Clamps*
Pressure Relief Valves*
Control Valves*
Control Solenoids*
Electronic Controls*
Vacuum Control Diaphragms*
Control Cables*
Control Linkages*
Purge Valves
Vapor Hoses
Liquid/Vapor Separator
Carbon Canister
Canister Mounting Brackets
Carburetor Purge Port Connector
*As related to the evaporative emission control system.
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 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 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 rights and responsibilities, please contact POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747) or visit polaris.com.
French: 1-800-268-6334
Present this section of your manual to your authorized POLARIS 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) |
|||
| DATE | HOURS | TECHNICIAN | SERVICE PERFORMED / COMMENTS |
|---|---|---|---|
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