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Owner's Manual

For Maintenance and Safety

SWITCHBACK ASSAULT

SKS

RMK

INDY ADVENTURE

INDY XCR

INDY XC

INDY SP

VOYAGEUR

WARNING

Operating, servicing, and maintaining a passenger vehicle or o-road

vehicle can expose you to chemicals including engine exhaust, carbon

monoxide, phthalates, and lead, which are known to the State of California

to cause cancer and birth defects or other reproductive harm. o minimize T

exposure, avoid breathing exhaust, do not idle the engine exce t as p

necessary, service your vehicle in a well-ventilated area and wear gloves

or wash your hands frequently when servicing your vehicle.

For more information go to www.P65Warnings.ca.gov/passenger-vehicle.

!WARNING

Read, understand, and follow all of the instructions and safety

precautions in this manual and on all product labels.

Failure to follow the safety precautions

could result in serious injury or death.

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

code with your smartphone.

2020 Owner’s Manual

Switchback Assault 144

RMK 144

SKS 146

Indy SP 129

Indy XC 129

Indy XCR 129

Indy SP 137

Indy XC 137

Indy XCR 137

Indy Adventure 137

Voyageur 144

POLARIS®, AXYS™, SWITCHBACK®, PERC®, RUSH®, XCR®, and LOCK

& RIDE® are trademarks of POLARIS Industries Inc.

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.

9929775 R02

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.

• Snowmobiles

• SPORTSMAN® All-terrain vehicles

• GEM® vehicles

• ® utility vehiclesRANGER

• SLINGSHOT® three wheel

motorcycles

• RZR® sport vehicles

• INDIAN® motorcycles

• POLARIS POWER® generators

• POLARIS DEFENSE® combat

vehicles

• Timbersled® Snow Bikes

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. Review the safety

DVD that came with your vehicle. POLARIS also recommends that all drivers

take the ROHVA safety e-course and a ROHVA hands-on safety training course.

Visit www.rohva.org or call 866-267-2751.

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.

WELCOME

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

DANGER indicates a hazardous situation which, if not avoided, WILL result in

death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, COULD result

in death or serious injury.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, COULD result

in minor to moderate injury.

NOTICE

NOTICE provides key information by clarifying instructions.

IMPORTANT

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.

SAFETY SYMBOLS AND SIGNAL WORDS

PRESERVATION OF THE ENVIRONMENT

POLARIS is committed to supporting an environmental education campaign. We

encourage state and provincial governments across the snowbelt to adopt

rigorous safety training programs that encourage protection of our environment,

including wildlife and vegetation.

Snowmobile clubs and other 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.

NOISE LEVEL

One of the most publicized issues about snowmobiles is noise. The Society of

Automotive Engineers (SAE), the standard-setting body for snowmobile

development, recommends that snowmobiles conform to prescribed sound

levels.

POLARIS snowmobiles are engineered to conform to these SAE standards. Our

muffler systems are designed to reduce noise levels and must not be altered or

removed. The sound of your snowmobile may not be welcome to non-

snowmobilers, so you have a responsibility to operate your snowmobile with

concern for others. We do our part by manufacturing quieter machines; we ask

your help to further reduce the impact of noise by operating your snowmobile

safely and responsibly.

AIR POLLUTION

POLARIS engineers continuously investigate ways to reduce emission levels of

two-stroke engines. We expect our efforts to lead to the reduction of potential air

pollution.

In addition to our technological research, we encourage government agencies,

manufacturers, distributors, dealers, ecologists, and other interested parties to

work together to develop data on environmental topics.

INTRODUCTION

VEHICLE IDENTIFICATION NUMBERS

Record your snowmobile's identification numbers and key number in the spaces

provided.

NOTICE

If installing an aftermarket tunnel wrap, do not cover the tunnel certification,

tunnel VIN or emissions certification labels with the wrap. If the tunnel wrap

doesn’t provide an opening for these labels, remove the section of wrap where

the labels are located.

Certification Label

Tunnel VIN

Emission Certification Label

VEHICLE MODEL NUMBER:

TUNNEL VIN (RIGHT SIDE OF TUNNEL):

ENGINE SERIAL NUMBER (ON RECOIL

HOUSING):

KEY NUMBER:

INTRODUCTION

ENGINE SERIAL NUMBER

The engine serial number

is located on the identification label on the engine

recoil cover.

600/800 Models 850 Models

KEY IDENTIFICATION

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.

INTRODUCTION

SAFETY

OPERATOR SAFETY

Follow the recommended maintenance program beginning on page 102 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.

WARNING

Driving a snowmobile requires your full attention. DO NOT drink alcohol or use

drugs or medications before or while driving or riding as a passenger. They will

reduce your alertness and slow your reaction time.

Snowmobiles are capable of traveling at high speeds. Use extra caution to

ensure operator safety. Make sure your snowmobile is in excellent operating

condition at all times. Always check major and vital safety components before

every ride.

All POLARIS snowmobiles are designed and tested to provide safe operation

when used as directed. Failure of critical machine components may result from

operation with any modifications, especially those that increase speed or

power. DO NOT MODIFY YOUR MACHINE. The snowmobile may become

aerodynamically unstable at speeds higher than those for which it is designed.

Loss of control may occur at higher speeds. Modifications may also create a

safety hazard and lead to bodily injury.

The warranty on your entire machine is terminated if any equipment has been

added, or any modifications have been made, to increase the speed or power

of the snowmobile.

SAFETY

STAY CLEAR OF TRACK

Your snowmobile is propelled by a revolving track that must be partially exposed

for proper operation. Do not stand on the plastic flap.

WARNING

Serious injuries may result if hands, feet, or clothing become entangled in the

track. Be alert when riding, and remain properly seated to stay clear of the

track. Never hold the snowmobile up or stand behind it while warming up the

track. A loose track or flying debris could cause serious injury or death. We

recommend having your dealer perform all track service and alignment

procedures.

STAY CLEAR OF ENGINE

Never attempt adjustments with the engine running. Turn off the ignition, open

the side panels or hood, make the adjustment, secure shields and guards,

secure the side panels and hood, and then restart the engine to check its

operation.

WARNING

Serious injury can occur if fingers or clothing contact the moving parts of an

engine. Always stop the engine before attempting adjustments.

RIDING POSITION

Operating a snowmobile requires skill and balance for proper control. Rider

positions may vary with experience and the features available on some

snowmobiles, but under many conditions, the proper position is to be seated

with both feet on the running boards and both hands on the handlebar grips for

proper throttle, brake and steering control.

WARNING

Improper riding position may reduce control and could result in serious injury or

death. Always ride in a position that allows for control of your vehicle.

RIDER CAPACITY

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.

SAFETY

RIDING APPAREL

CLOTHING

WARNING

Avoid wearing loose clothing or long scarves, which can become entangled in

moving parts and cause serious injury. Always wear an approved helmet and

eye protection.

Be prepared, be warm and be comfortable

when riding. Be aware of the weather

forecast, especially the windchill, and dress

accordingly. See page 26.

HELMET

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.

SAFETY

EYE PROTECTION

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding

a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof

helmet face shield. POLARIS recommends wearing approved Personal

Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or

CE. Make sure protective eye wear is kept clean.

SURVIVAL PREPARATION

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

EXCESSIVE SPEED

WARNING

High speed driving, especially at night, could result in serious injury or death.

Always reduce speed when driving at night or in inclement weather.

Always observe all state and local laws governing snowmobile operation and

speed limits. Always be alert and pay attention to the trail ahead. If your speed is

40 MPH (64 km/h), your snowmobile is traveling about 60 feet (18 m) per

second. If you look back for only two seconds, your snowmobile will travel about

120 feet (36 m). If your speed is 60 MPH (96 km/h), your snowmobile will travel

about 180 feet (55 m) in two 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.

SAFETY

DRIVER AWARENESS

Slow down when traveling near poles, posts, or other obstacles. Be especially

alert if you're snowmobiling after dark. Always be on the alert for wire fences.

Single strands are especially dangerous, since there may be a great distance

between posts. Guy wires on utility poles are also difficult to distinguish.

Make sure the way is clear before crossing railroads

and other roads and highways. The noise of your

snowmobile will drown out the sound of approaching

vehicles. Look ahead, behind, and to both sides before

turning or crossing railroad tracks or highways. Steep

embankments may also hide your view. Always leave

yourself a way out.

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.

DISABLED OPERATORS

Safe operation of this rider-active vehicle requires good judgement and physical

skills. Operators with cognitive or physical disabilities have an increased risk of

loss of control, which could result in serious injury or death.

SAFETY

MOUNTAINOUS TERRAIN RIDING

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.

WARNING

An avalanche can occur at any time, in any conditions and on any slope.

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.

SAFETY

GET THE SAFETY GEAR

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

SAFETY

GET TO KNOW YOUR SAFETY GEAR

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.

SAFETY

GET THE PICTURE

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.

NOTE

The 30º slope graphic is for illustration purposes only. The risk of an avalanche

is always present in mountainous terrain, regardless of slope angle.

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

GET OUT OF HARM’S WAY

• 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.

SAFETY

GET THE FORECAST

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.

GET AVALANCHE SAFETY TRAINING

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.

AVALANCHE AWARENESS

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.

SAFETY

North American Public Avalanche Danger Scale

Avalanche danger is determined by the likelihood, size and distribution of

avalanches.

DANGER LEVEL TRAVEL ADVICE LIKELIHOOD

AVALANCHES

AVALANCHE

SIZE AND

DISTRIBUTION

Extreme

Avoid all avalanche

terrain.

Natural and

human-triggered

avalanches

certain.

Large to very

large avalanches

in many areas.

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.

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.

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.

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.

SAFETY

ICE AND SNOW BUILD-UP

WARNING

Ice and snow build-up may interfere with the steering of your snowmobile,

resulting in serious injury or death. Keep the underhood area free of snow and

ice.

Before driving, manually turn the skis to the left and right to be sure ice and

snow are not interfering with full left and right steering. If difficulty is

encountered, remove ice and snow build-up that may be obstructing the steering

linkage.

DRIVING ON SLIPPERY SURFACES

WARNING

Never attempt an abrupt change of direction when operating on slippery

surfaces. Proceed slowly and use extra caution. Driving on ice or hard-packed

snow reduces steering and braking control, which may result in loss of control

and serious injury or death. Slow down and use extra caution when operating

on slippery surfaces.

INADEQUATE SNOW CONDITIONS

Since snow provides the only lubrication for the power slide suspension and, on

liquid cooled models, cooling for the engine, adequate snow cover is a

requirement for operation of your snowmobile.

NOTICE

Driving in too little snow will result in excessive wear and damage to the slide

rail, track and/or engine.

WARNING

Inadequate cooling and lubrication will lead to overheating of the slide rail and

track, causing premature wear, damage and failure, which can result in serious

injury. Reduce speeds and frequently drive into fresh snow to allow adequate

cooling and polishing of the slide rail and track surfaces. Avoid operating for

prolonged periods on ice, hard-packed surfaces or roads.

OPERATING IN DEEP SNOW

If the snowmobile becomes stuck in snow, clear the running board area of snow,

then step down the snow in front of the snowmobile so that when the throttle is

opened, the snowmobile will be able to climb up and over the snow.

SAFETY

DRIVING DOWNHILL

When riding downhill, shift your weight to the rear of the snowmobile and reduce

your speed to a minimum. Apply just enough throttle to keep the clutch engaged,

allowing the engine's compression to help slow the snowmobile and keep it from

rolling freely downhill.

WARNING

When driving on long downhill stretches, pump the brakes. Riding the brakes

may cause the brake system to overheat, which may result in brake failure.

Excessive or repetitive use of the brakes for high speed stops will also cause

an overheated brake system. This condition may lead to a sudden loss of

brakes and/or fire and may result in serious injury or death.

DRIVING IN HILLY TERRAIN

WARNING

Climbing a hill or crossing the face of a slope may result in loss of balance and

snowmobile rollover, causing serious injury or death. Use caution and good

judgement when driving in hilly terrain.

Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable,

keep your weight low and forward. If you must cross the face of a slope, keep

your weight on the uphill side of the snowmobile to maintain proper balance and

avoid possible roll-over.

Slow down when 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.

SAFETY

DRIVE BELT

Do not operate the engine with the drive belt removed.

Any servicing that requires operation without a belt can be performed by your

dealer.

WARNING

Operation of the engine with the belt removed may result in injury or damage to

the engine.

INTAKE SILENCER

Do not operate the engine with the intake silencer or filter removed.

NOTICE

Damage to the engine may occur if the intake silencer or filter are removed.

CLUTCHES

Do not attempt to service the clutches.

All clutch service can be performed by your dealer. The clutch is a complex

mechanism that rotates at high speeds. Each clutch is dynamically balanced

before installation. Any tampering may disrupt this precision balancing and

create an unstable condition.

COLD WEATHER DRIVE-AWAY

Whenever your 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.

MANEUVERABILITY

While much control and maneuverability is achieved through the steering

system and skis, maximum control is achieved by the shifting of your body

weight. Maneuverability will change based on rider weight and foot position on

running boards.

SAFETY

DRIVING RESPONSIBLY

Every snowmobile handles differently, and even the most docile conditions may

become dangerous if operators drive improperly. If you're new to snowmobiling,

acquaint yourself with the snowmobile and with what it will and won't do under

various conditions. Even seasoned drivers should spend some time getting the

feel for a snowmobile before attempting ambitious maneuvers.

• 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.

SAFETY

WINDCHILL/TEMPERATURE CHARTS

The following information is provided to help you determine when temperatures

become dangerous for riding.

WINDCHILL CHART (°F)

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.

WINDCHILL CHART (°C)

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.

SAFETY

TUNNEL WARNING

The Tunnel Warning label is located on the rear of the tunnel.

WARNING

Hot Surface

Do Not Touch

Burn may result. Entire top of tunnel may be hot. Install

only accessories specifically approved for this model

by Polaris.

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.

CLUTCH WARNING/BELT REMOVAL

The clutch warning label

is found on the oil bottle:

WARNING

Do not operate engine with hood or side

panels open.

Do not attempt adjustment with engine

running.

Do not operate engine with the clutch guard

removed.

Never run engine with drive belt removed.

Never service clutches yourself. Your dealer

can perform this service.

BELT REMOVAL - ALL UNITS

1. For electric reverse models, engine must be stopped in forward to allow

clutch opening.

2. Install L-wrench from fender into the open threaded hole in the driven clutch.

3. 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.

SAFETY

OPERATION WARNING

The operation warning label is located on the console.

WARNING

• To avoid serious injury or death, read and understand all warnings and the

Owner's Manual before operation. If manual is missing, contact a POLARIS

dealer for a replacement.

• This vehicle is capable of high speeds. Buried objects or uneven terrain can

cause loss of control. Reduce speed and use extreme caution when operating

in unfamiliar terrain.

• Excessive speed, especially at night or with limited visibility, can result in

insufficient time for you to react to terrain changes, to avoid unexpected

obstacles, or to stop safely.

• Never consume alcohol or drugs before or while operating this vehicle.

• In an emergency, push down the Auxiliary Shut-Off Switch, located on the top

of the throttle control assembly, to stop the engine. Then pull the brake lever

to stop.

• Always wear an approved helmet, eye protection, and adequate clothing

while operating this vehicle.

• This vehicle is designed for adult use only. Check local laws for age

requirements.

• When operating with a passenger (on approved models only) reduce speed

and allow extra space for steering and stopping. A passenger reduces your

ability to control the vehicle.

• When operating on hard-packed snow, ice, or when crossing roads, steering

and braking ability are greatly reduced. Reduce speed and allow extra space

to turn or stop.

• To maintain vehicle control on ice or hard-packed surfaces, you should have a

proper balance of ski carbides to track studs. See Owner's Manual for proper

use of traction products.

• Repeated stops from high speed may cause fading or sudden loss of braking

ability.

• Parking brake may relax when used for long periods. Do not leave brake

engaged for more than five minutes.

• Before starting engine, check throttle, brake, and steering for proper

operation. Make sure hood and side panels are latched. Be seated and in

position to control the vehicle.

Oil injection system: Use unmixed fuel only. Check oil level when refueling.

SAFETY

FEATURES

COMPONENT LOCATIONS

NOTE

The figures below are for reference only. Your model may differ slightly.

q Skis i Operator Seat h Independent Front

Suspension

w Nosepan o Taillight j Side Panel

e Front Bumper a Rear Bumper k Torsion Spring

r Hood s Snow Flap l Rear Track Shock

t Headlight d Upper Control Arm 1( Front Track Shock

y Windshield (accessory) f Lower Control Arm 2) Rail

u Handlebar g Spindle

FEATURES

CONTROLS

NOTE

The figures below are for reference only. Your model may differ slightly.

q Brake Lever

w Parking Brake Lock

e Ignition Switch

r Instrument Cluster

t Engine Stop Switch

y Throttle Control

u Recoil Starter Handle

i Handlebar Grip Warmer Switch

o Thumb Warmer Switch

a Electronic Reverse Button

s Headlight Dimmer Switch

d MODE/SET Switch

FEATURES

IGNITION SWITCH

OFF Vehicle / PIDD power off

RUN Vehicle / PIDD power on

START Activates starter motor (if

equipped)

The ignition switch has three positions: OFF, RUN, and START.

If equipped with electric start, turn the key to START to crank the engine. When

the key is released, it automatically returns to the RUN position.

NOTE

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 or when the engine is transitioning between forward and reverse

operation. If a battery is not installed, the PIDD reboots when the engine is

started and when electronic reverse (PERC) is used.

FEATURES

12-VOLT DC POWER RECEPTACLE

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.

NOTE

The 12-volt DC power receptacle and the jumper harness required to connect

the receptacle to the hood wiring harness can be purchased from your

POLARIS dealer.

12-VOLT RCA POWER SOURCES

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.

12-VOLT RCA ADAPTER

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.

12-VOLT RCA POWER PLUG

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.

FEATURES

ADJUSTABLE HEADLIGHT

NOTE

The image below is for reference only. Your model may differ slightly.

The headlight can be adjusted for vertical aim using the following procedure.

1. In a well-ventilated area, position the snowmobile on a level surface with the

headlight approximately 25 feet (7.6 m) from a wall

2. Place the rider or the approximate weight of the rider on the seat or tunnel

floorboards.

3. Measure the distance from the floor to the center of the headlight and make a

mark on the wall at the same height.

4. Start the engine. Move the headlight switch to high beam.

5. Observe the headlight aim on the wall. The most intense part of the headlight

beam should be two inches (5 cm)

w below the mark on the wall.

6. 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.

FEATURES

TOOLS

The belt removal L-wrench tool, spare belt, spark plug, and spark plug tool

container are located behind the left engine compartment panel.

NOTE

Spare belt and spark plugs are not provided with the snowmobile.

L-WRENCH

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.

SPARK PLUG WRENCH

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.

REPLACEMENT DRIVE BELT

To insert a replacement drive belt into the spare drive belt container, do the

following:

1. Rotate the spark plug wrench counter-clockwise to release it from the

bracket.

2. Pull the wrench upward to remove it.

3. Tilt the container until the bracket detaches from the bumper tube.

4. Pull the container out of the compartment.

5. When placing a drive belt into the container, fold the belt as shown. Verify

that the belt loop at the rear of the container is positioned slightly higher than

the front loop.

6. Slide the container into the engine compartment at an angle.

7. Position the container bracket onto the bumper tube and rotate it downward.

8. Reinstall the spark plug wrench into the bracket and through the hole in the

bumper tube.

9. Rotate the spark plug wrench clockwise until it locks into place.

FEATURES

RAIL SCRATCHERS

Some models are equipped with rail scratchers to help prevent overheating

when riding on ice or hard-packed snow.

NOTICE

Do not install accessory bogie wheels on the inside of the rail beams if your

model is equipped with a remote reservoir rear track shock or damage will

occur. The rail scratchers must be removed as they interfere with the

accessory bogie wheels.

DETONATION ELIMINATION TECHNOLOGY

(DET)

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.

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.

NOTE

The instrument cluster alert indicates which cylinder is experiencing detonation

NOTE

The most likely causes of severe detonation are outlined in the troubleshooting

table below.

FEATURES

OIL PUMP FAILURE PROTECTION (IF

EQUIPPED)

If the ECU determines there is 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.

EXTENDED IDLE ENGINE SHUTOFF

This engine feature causes the ECU to shut down the engine when engine

temperature reaches 120° F (50° C) and there is no throttle lever input for five

minutes.

NOTE

If equipped with an PIDD, the gauge will remain on because the key is in the

ON position.

SECURITY SYSTEM (IGNITION LOCK SYSTEM)

Your snowmobile has an optional security function that can be activated by an

authorized POLARIS dealer. If you have this feature activated, you can lock the

ignition to prevent unauthorized use when leaving the snowmobile unattended.

A locked system will limit engine speed to 3000 RPM, which prevents clutch

engagement, and the snowmobile will not move when throttle is applied.

If your model is equipped with the POLARIS Interactive Digital Display (PIDD),

please see the PIDD Owner’s Manual provided with your snowmobile.

FEATURES

GAUGE

STANDARD INSTRUMENT CLUSTER

q Check Engine

w Engine Hot

e Low Oil

r Low Battery Voltage

t Playback

y Low Fuel

u High Beam

i Parking Brake

o Reverse

a Security

NOTICE

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 s on the Left Hand Control.

GAUGE

INDICATOR LAMPS

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.

GAUGE

RIDER INFORMATION CENTER

The rider information center is located in the instrument cluster. The center

displays vehicle speed, engine speed, odometer, resettable trip meters (2), total

engine hours of operation, fuel level, engine temperature, and a diagnostic

display mode.

Setting changes must be made with the engine running or with the vehicle

set to display standard units of measurement for distance and temperature.

q 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.

w Speed Display - The speed display area displays either vehicle speed or

engine speed.

e 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.

NOTE

The low fuel indicator and fuel level gauge on the Standard Instrument Cluster

are not supported on models with a fuel level gauge on the fuel cap.

GAUGE

TIP

If the fuel icon fails to display, an open or short circuit has occurred in the fuel

sensor circuit. See your dealer.

r Odometer/Engine Hour Display - This area displays the odometer, Trip A,

Trip B and engine hours.

INFORMATION DISPLAY AREA

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.

SPEED DISPLAY AREA

The speed display area displays either vehicle speed or engine speed. Vehicle

speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h).

Engine speed is displayed in revolutions per minute (RPM).

1. To change which item displays, first make sure the information display area

is set to display either engine speed or vehicle speed.

2. Press and release the center button.

FUEL GAUGE (IF EQUIPPED)

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.

NOTE

The low fuel indicator and fuel level gauge on the Standard Instrument Cluster

are not supported on models with a fuel level gauge on the fuel cap.

TIP

If the fuel icon fails to display, an open or short circuit has occurred in the fuel

sensor circuit. See your dealer.

GAUGE

ODOMETER/ENGINE HOUR DISPLAY AREA

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.

PLAYBACK FUNCTION

The playback function allows the rider to record and play back engine speed,

vehicle speed and throttle position sensor information for up to three minutes.

TO RECORD

1. Press and hold the center button on the instrument cluster to enter the

Options Menu.

2. Press and release the MODE button until PLAYBACK appears in the

information display area.

GAUGE

3. Press and release the SET button.

RECORD will appear in the information display area.

4. 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.

NOTE

To stop recording at any time during the recording process, press and release

the SET button.

TO PLAYBACK

1. To play back the recorded data, stop the vehicle and wait for engine speed to

drop below clutch engagement.

2. Press and hold the center button on the instrument cluster to enter the

Options Menu.

3. Press and release the MODE button until PLAYBACK appears in the

information display area.

GAUGE

4. Press and release the SET button twice.

PLAY will appear in the information display area.

5. Press and release the SET button to play the recorded data.

Once playback has concluded, REPLAY will appear in the information

display area.

6. Press and release the SET button to REPLAY recorded data.

7. Press and release the MODE button to end playback and return to the

Options Menu.

STANDARD/METRIC DISPLAY

The odometer and temperature displays can be viewed in either standard or

metric units of measurement. Both displays change if units are changed. The

new settings will remain until changed by the operator.

Change Method 1

1. Press and hold the center button on the instrument cluster to enter the

Options Menu.

2. Press and release the MODE button until engine temperature appears in the

information display area.

3. Press and release the SET button or SET switch to change units.

GAUGE

Change Method 2

1. Press and release the SET button or SET switch until the odometer appears

in the information display area.

2. Press and hold the SET button or SET switch until the units change.

SECURITY SYSTEM (IGNITION LOCK SYSTEM)

This system is an optional feature and will not function until it has been activated

by your authorized POLARIS dealer. If you have this feature activated, you can

lock the ignition to prevent unauthorized use when leaving the snowmobile

unattended. A locked system will limit engine speed to 3000 RPM, which

prevents clutch engagement, and the snowmobile will not move when throttle is

applied.

If you wish to use this feature, you must complete all four tasks on the following

pages to have your system activated and to change the security code to one of

your own choosing.

FIRST TIME USE OF YOUR SECURITY SYSTEM

Perform all tasks in the order shown if you wish to activate and use the optional

security system.

TASK 1: Activate the security system

See your authorized POLARIS dealer to have the optional security system

feature activated in the electronic control unit (ECU).

TASK 2: Lock the System the First Time

NOTE

To lock the system for the first time, use code 000.

GAUGE

1. Press and hold the center button on the instrument cluster to enter the

Options Menu.

2. Press and release the MODE button until SECURITY OFF appears in the

information display area.

3. Press and release the SET button.

ENTER CODE will appear in the information display area.

4. Press and release the SET button to increase the 1st digit.

5. Press and hold the SET button to accept the 1st digit and advance to the 2nd

digit.

6. Press and release the SET button to increase the 2nd digit.

GAUGE

7. Press and hold the SET button to accept the 2nd digit and advance to the 3rd

digit.

8. 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.

GAUGE

TASK 3: Unlock the System

NOTE

To unlock the system for the first time, use code 000.

1. While the engine is running, Press and release the SET button.

ENTER CO will appear in the information display area.

2. Press and release the SET button to increase the 1st digit.

3. Press and hold the SET button to accept the 1st digit and advance to the 2nd

digit.

4. Press and release the SET button to increase the 2nd digit.

GAUGE

5. Press and hold the SET button to accept the 2nd digit and advance to the 3rd

digit.

6. Press and release the SET button to increase the 3rd digit.

7. 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

NOTE

The system is now unlocked .

If code is incorrect, BAD CODE will appear in the information display area.

Return to step 1 to re-enter code.

8. You must now enter a new security code. Proceed immediately to TASK 4.

GAUGE

TASK 4: Enter Your New Security Code

1. 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.

2. Press and release the SET button to increase the 1st digit.

3. Press and hold the SET button to accept the 1st digit and advance to the 2nd

digit.

4. Press and release the SET button to increase the 2nd digit.

5. Press and hold the SET button to accept the 2nd digit and advance to the 3rd

digit.

GAUGE

6. Press and release the SET button to increase the 3rd digit.

7. 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

NOTE

Your new code is now set. The system is NOT locked.

8. Record your new security code in a safe place for future reference.

Record your new personal security code here: __________________

TIP

If you lose your personal security code, see your dealer to have the code reset

to “000”. Then perform TASK 2 through TASK 4 to change the code to one of

your own choosing.

GAUGE

LOCKING SYSTEM WITH PERSONAL SECURITY CODE

1. Start the engine.

2. Press and hold the center button on the instrument cluster to enter the

Options Menu.

3. Press and release the MODE button until SECURITY OFF appears in the

information display area.

4. Press and release the SET button.

ENTER CODE will appear in the information display area.

5. Press and release the SET button to increase the 1st digit.

6. Press and hold the SET button to accept the 1st digit and advance to the 2nd

digit.

GAUGE

7. Press and release the SET button to increase the 2nd digit.

8. Press and hold the SET button to accept the 2nd digit and advance to the 3rd

digit.

9. 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.

GAUGE

UNLOCKING SYSTEM WITH PERSONAL SECURITY

CODE

1. While the engine is running, Press and release the SET button.

ENTER CODE will appear in the information display area.

2. Press and release the SET button to increase the 1st digit.

3. Press and hold the SET button to accept the 1st digit and advance to the 2nd

digit.

4. Press and release the SET button to increase the 2nd digit.

5. Press and hold the SET button to accept the 2nd digit and advance to the 3rd

digit.

GAUGE

6. Press and release the SET button to increase the 3rd digit.

7. 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

NOTE

The system is now unlocked.

If code is incorrect, BAD CODE will appear in the information display area.

Return to step 1 to re-enter code.

CHANGING TO A NEW SECURITY CODE

Any time you wish to change your current security code to a new code, perform

TASK 2 through TASK 4 of the First Time Use of Your Security System

procedure. Instead of using the factory default code “000” in TASK 2 and TASK

3, use your current security code.

GAUGE

SECURITY SYSTEM ACCESS QUICK REFERENCE

Now that you have become familiar with the procedure for locking and unlocking

the system, use the chart below as a quick reference.

SECURITY SYSTEM ACCESS QUICK REFERENCE CHART

Action Result

1. Start engine

2. Press and hold the

center button

3. Press and release the

SET button until

SECURITY appears in

information display

area.

4. Press and release

SET button.

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.

GAUGE

DIAGNOSTIC DISPLAY MODE

The diagnostic display mode is for

informational purposes only. Your

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 POLARIS dealer can help

retrieve inactive codes.

Use the following procedure to view active codes.

1. Do not stop the engine.

2. Press and hold the center button on the instrument cluster to enter the

Options Menu.

3. 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.

TIP

When the diagnostic mode is displayed, the check engine warning indicator will

begin to flash.

4. 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.

5. 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.

6. See Diagnostic Trouble Codes for code definitions and failure descriptions.

GAUGE

POLARIS INTERACTIVE DIGITAL DISPLAY

(PIDD)

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

CAUTION

Use a microfiber hand towel to clean the LCD screen. Certain products will

damage the screen and other plastic surfaces. Do not use alcohol to clean the

display screen. Immediately clean off any gasoline that splashes on the

instrument cluster.

NOTICE

The speedometer may give wrong values at the existence of electromagnetic

radiation >= 10 V/m.

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 q 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.

GAUGE

PERIODIC MAINTENANCE SCHEDULE

ITEM

FREQUENCY / INTERVALS

150

MI.

(240

KM)

500

MI.

(800

KM)

1000

MI.

(1600

KM)

2000

MI.

(3200

KM)

PRE-

SEA-

SON

L = LUBRICATE / I = INSPECT OR ADJUST / R = REPLACE / C = CLEAN

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

105

MAINTENANCE

LUBRICATION

REAR SUSPENSION

Lubricate the suspension pivot shafts with POLARIS All Season Grease at the

intervals outlined in the Periodic Maintenance Table beginning on page 103 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.

CHAINCASE OIL (IF EQUIPPED)

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.

OIL LEVEL CHECK

1. Position the snowmobile on a level surface.

2. Remove the fill plug.

3. Using a funnel, slowly add the recommended oil until the fluid begins to

overflow.

4. Clean the area with a clean, dry shop towel. Reinstall the fill plug.

106

MAINTENANCE

TORQUE

4-4.9 ft-lbs (5.4-6.6 Nm)

OIL CHANGE (PUMP METHOD)

NOTE

This procedure requires the use of a commercially available hand pump oil

extractor.

1. Elevate the front of the snowmobile using a floor jack or appropriate lift.

2. Remove the fill plug. Clean all metal shavings off the plug.

3. Insert the tube of a hand pump oil extractor into the fill hole. Direct the hose

toward the bottom front area of the cover, away from the chain/sprocket.

4. Extract the oil from the chaincase.

5. Lower the snowmobile.

6. Using a funnel, slowly add the recommended oil until the fluid begins to

overflow. Maximum fluid capacity is 10.5 oz. (310 ml).

7. Clean the area with a clean, dry shop towel.

8. Reinstall the fill plug.

TORQUE

4-4.9 ft-lbs (5.4-6.6 Nm)

107

MAINTENANCE

OIL CHANGE (COVER DRAIN METHOD)

1. Position the snowmobile on a level surface.

2. Remove the two (2)screws securing the fender to the chaincase

3. Remove the right side panel. If equipped with a battery, remove the battery.

4. Place a drain pan under the chaincase.

5. Loosen (do not remove) the three (3) chaincase cover screws

6. Carefully pry the cover open.

NOTICE

DO NOT insert a screwdriver or pry bar between the cover and chaincase.

Seal damage may occur.

7. Allow the oil to drain completely.

108

MAINTENANCE

8. Tighten the cover screws

TORQUE

6-10 ft-lbs (8-13 Nm)

9. Remove the fill plug

e. Clean all metal shavings off the plug.

10. Using a funnel, slowly add the recommended oil until the fluid begins to

overflow. Maximum fluid capacity is 10.5 oz. (310 ml).

11. Clean the area with a clean, dry shop towel.

12. Reinstall the fill plug

TORQUE

4-4.9 ft-lbs (5.4-6.6 Nm)

13. Reinstall the battery(if equipped).

14. Reinstall the screws securing the fender to the chaincase.

OIL LINES

Inspect oil line condition every 1000 miles (1600 km).

109

MAINTENANCE

SIDE PANEL/HOOD

CAUTION

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

SIDE PANELS

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.

HOOD

To remove the hood, do the following:

1. Remove the left and right side panels.

2. Rotate the 1/4 turn fasteners

at the rear corners if the hood.

3. Disconnect the hood wire harness connector

4. Remove the hood assembly from the vehicle.

NOTE

Store the hood in a position that will not damage the brake cooler duct.

110

MAINTENANCE

INTAKE FILTERS

The intake foam filters

limit snow

ingestion into the intake system. When

operating in loose powder snow, check

the foam filters periodically to remove

any accumulation of snow.

FUEL PUMP

All fuel pump service must be performed by an authorized POLARIS dealer. Do

not attempt to service the fuel pump.

FUEL FILTER / FUEL LINES

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

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 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.

NOTICE

Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may

cause damage to the lines. If a fuel line has been damaged or kinked, replace

it promptly.

SPARK PLUGS

SPARK PLUG RECOMMENDATIONS

NOTE

Using non-recommended spark plugs can result in serious engine damage. A

spark plug with a heat range too high will always cause engine damage if the

engine is operated in conditions more severe than intended for that plug.

Always use the spark plugs recommended for your snowmobile.

111

MAINTENANCE

A new engine can cause temporary spark plug fouling due to the preservative

added during the assembly process. Avoid prolonged idle speeds, which cause

plug fouling and carbonization.

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.

TORQUE

18-22 ft. lbs. (24-30 Nm)

• Always carry spare spark plugs.

SPARK PLUG INSPECTION

Spark plug condition is indicative of engine operation. The spark plug firing end

condition should be read after the engine has been warmed up and the vehicle

has been driven at higher speeds. Immediately check the spark plug for correct

color.

WARNING

A hot exhaust system and engine can cause burns. Wear protective gloves

when removing a spark plug for inspection.

1. Remove the left side panel and hood.

2. Remove the spark plug cap.

3. Using the spark plug wrench provided in the tool kit, rotate the spark plug

counter-clockwise to remove it.

4. Reverse the procedure for spark plug installation. Torque to specification.

5. Reinstall the spark plug cap. Verify an “audible” click is heard when installing

the plug cap.

112

MAINTENANCE

SPARK PLUG CONDITION

NORMAL PLUG

The normal insulator tip is gray, tan or light brown. There will be few combustion

deposits. The electrodes are not burned or eroded. This indicates the proper

type and heat range for the engine and the service.

TIP

The tip should not be white. A white insulator tip indicates overheating, caused

by use of an improper spark plug or incorrect carburetor/throttle body

adjustments.

WET FOULED PLUG

The wet fouled insulator tip is black. A damp oil film covers the firing end. There

may be a carbon layer over the entire nose. Generally, the electrodes are not

worn. General causes of fouling are excessive oil or use of non-recommended

injection oil.

COOLING SYSTEM

COOLANT

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 dealer can assist.

To ensure that the coolant maintains its ability to protect the engine, we

recommend that the system be completely 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.

NOTICE

If coolant flow becomes restricted or plugged, coolant loss, air lock, or engine

damage may result. Most cooling systems are equipped with a filter that should

be periodically inspected or replaced.

COOLANT LEVEL

The engine coolant level is controlled by the recovery system. The recovery

system components are:

• Coolant bottle/overflow tank

• Pressure cap

113

MAINTENANCE

• Connecting hoses

• In-bottle Thermostat (850 models only)

Always maintain the coolant level at or slightly above the FULL COLD mark on

the coolant bottle (when the engine is cold).

1. Stop the engine.

2. Open the right side panel.

3. View the coolant level in the coolant bottle. Add coolant as needed.

NOTICE

Operating the snowmobile with insufficient coolant will result in overheating

and serious engine damage. Always maintain the coolant level as

recommended.

FLUSHING THE COOLING SYSTEM

To ensure that the coolant maintains its ability to protect the engine, we

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 POLARIS dealer can check the coolant when performing

the fall tune-up on your snowmobile.

BLEEDING THE COOLING SYSTEM (600/800

MODELS)

WARNING

Steam and hot liquids will cause burns to your skin. Never bleed the cooling

system or remove the pressure cap when the engine is warm or hot.

Use of a non-standard pressure cap will not allow the recovery system to

function properly. If the pressure cap needs replacement, contact your dealer for

the correct part.

NOTICE

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 page 113.

114

MAINTENANCE

1. Open the side panels and remove the hood.

2. Close the side panels.

WARNING

Never operate a snowmobile with the side panels open or removed.

3. Position the snowmobile with the right ski and control arms elevated at a 45-

degree angle.

4. Fill the coolant bottle to the COLD FILL mark.

5. Install the coolant bottle cap to the first lock. Do not tighten to the fully seated

position.

6. Lock the parking brake.

7. Start the engine and allow it to run at a fast idle for several minutes, until the

heaters are warm to the touch. Loosen the bleed screw occasionally to purge

any trapped air.

8. When all heater extrusions are warm to the touch, stop the engine.

9. Allow the engine and cooling system to cool. Secure the bleed screw.

10. Fill the coolant bottle to the COLD FILL mark. Reinstall the bottle cap

securely.

11. Carefully lower the front end of the snowmobile.

12. Open the side panels and reinstall the hood. Close the side panels.

BLEEDING THE COOLING SYSTEM (850 MODELS)

The cooling system is a self bleeding system.

CAUTION

Cooling system under pressure. 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. Wear eye protection when servicing the cooling system.

NOTICE

Pressure cap rated at 13 PSI (0.9 BAR). Use of a non-standard pressure cap

will not allow the recovery system to function properly.

115

MAINTENANCE

CAUTION

Perform this procedure in a well-ventilated area. Use the recommended 50/50

Extended-Life Antifreeze.

1. Open the side panels and remove the hood.

2. Close the side panels.

3. Fill the coolant bottle to the COLD FILL mark.

4. Install the coolant bottle cap to the first lock. Do not tighten to the fully seated

position.

5. Lock the parking brake.

6. Start the engine and allow it to run at a fast idle for several minutes, until the

heaters are warm to the touch.

CAUTION

Keep the coolant level in the coolant bottle at or near the COLD FILL mark

when engine is running. The engine may suck the coolant down quickly which

my require coolant to be added a few times to stabilize the coolant level.

7. When all heater extrusions are warm to the touch, stop the engine.

8. Allow the engine and cooling system to cool.

9. Fill the coolant bottle to the COLD FILL mark. Reinstall the bottle cap

securely.

10. Open the side panels and reinstall the hood. Close the side panels.

EXHAUST SYSTEM

Check the exhaust system for wear or damage at approximately 2000 miles

(3200 km). Always allow the engine and exhaust system to cool completely

before inspecting.

WARNING

Hot exhaust system parts can cause burns. Allow adequate time for the

exhaust system to cool. Never perform this procedure with the engine running.

1. Open the side panels and remove the hood.

2. Inspect the muffler and pipes for cracks or damage.

3. Check for weak or missing retaining springs or damper/support grommets.

116

MAINTENANCE

4. Check for loose clamps on the pipe covers.

5. Reinstall the hood and side panels.

DRIVE CHAIN TENSION

Check drive chain tension weekly and before each long trip.

1. Remove the side panels.

2. Rotate the driven clutch counter-clockwise to move all chain slack to the

tensioner side. Lock the brake lever lock, or have an assistant hold the brake

lever firmly.

3. Loosen the adjuster bolt jam nut

4. Finger tighten the adjuster bolt

until it can no longer be adjusted by hand,

then back off 1/4 turn.

5. Tighten the jam nut while holding the adjuster bolt.

TORQUE

21 ft. lbs. (28 Nm)

6. Reinstall the side panels.

7. Release the brake lever lock.

117

MAINTENANCE

BRAKES

HYDRAULIC BRAKE INSPECTION

Inspect the brake lever reserve before each use of the snowmobile. See page

85.

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.

WARNING

Brake failure during operation can result in serious injury or death. Properly

functioning brakes are vital to your safety. Be sure the brake pads do not drag

on the disc and that brake lever travel is not excessive. Always replace brake

pads when the brake pad material becomes thinner than the backing plate

(approximately 1/16 inch or 1.5 mm).

BRAKE COMPONENTS

Brake Caliper

Brake Disc

Brake Pad Material - Replace when

thickness is less than 1/16 inch (1.5

mm).

EXCESSIVE LEVER TRAVEL

Hydraulic brakes are self-adjusting, but if excessive brake pad clearance

develops, bring the snowmobile to an authorized POLARIS dealer for inspection

and adjustment.

TIP

The lightweight brake discs have vent holes that may cause a high-pitched

sound during operation.

118

MAINTENANCE

BRAKE FLUID

The brake fluid level can be seen through a plastic sight glass in the brake

reservoir. If the fluid is sufficient, the sight glass will be black. If the sight glass is

any color other than black, add brake fluid.

Replace brake fluid at least every two years with POLARIS DOT 4 high

temperature brake fluid, or an equivalent product.

WARNING

After opening a bottle of brake fluid, always discard any unused portion. Never

store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly

absorbs moisture from the air. The moisture causes the boiling temperature of

the brake fluid to drop, which can lead to early brake fade and the possibility of

accident or serious injury.

WARNING

Keep the master cylinder cover free of dirt and debris. The vent slits allow for

diaphragm movement, and if they become plugged, movement of brake fluid

below the diaphragm may be restricted, altering brake function.

NOTICE

Brake fluid will damage labels, paint and some plastics. Always wipe up spills

immediately.

119

MAINTENANCE

BLEEDING THE HYDRAULIC BRAKE SYSTEM

Air in the hydraulic brake system will cause spongy brake lever action. Bleed the

system before operating the snowmobile.

WARNING

Operating the vehicle with a spongy brake lever can result in loss of brakes,

which could cause an accident and lead to serious injury or death. Never

operate the vehicle with a spongy-feeling brake lever.

CAUTION

Hot exhaust system parts can cause burns. Allow adequate time for the

exhaust system to cool. Never perform this procedure with the engine running.

During the bleeding procedure, keep the brake handle as level as possible. The

reservoir must be in this position to minimize the possibility of air entering the

system through the reservoir vent.

1. Remove the brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX marks or 1/4-

5/16 inch (.6-.8 cm) below the lip of the reservoir opening. Reinstall the

gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid

into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder valve 3/4 of

a turn to release air.

5. Close the bleeder valve and release the brake lever.

6. Repeat steps 4–5 until fluid flows from the bleeder valve in a solid stream

free of air bubbles.

WARNING

Overfilling the master cylinder leaves no room for fluid expansion and may

cause the brakes to lock, resulting in serious injury or death. Always add brake

fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level. See page

119.

8. Reinstall the gasket and cover.

120

MAINTENANCE

LIGHTS

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.

FUSE REPLACEMENT

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.

NOTICE

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.

CONSTANT POWER FUSE

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.

CLUTCH SYSTEM

Periodically inspect clutch sheaves for damage, wear or belt residue. To

maintain optimum performance, clean with non-oil based cleaners such as

isopropyl alcohol.

WARNING

If you become aware of higher than normal clutch engagement or an unusual

vibration or shift pattern, see your dealer or qualified person immediately. Do

not operate the snowmobile until repairs have been made.

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.

NOTICE

The bushings in the weights and rollers of POLARIS clutches are made of a

material that may be damaged if lubricated. Do not lubricate clutch bushings.

121

MAINTENANCE

CLUTCH ALIGNMENT OFFSET

Clutch alignment offset is important for maintaining optimum performance. Your

dealer can perform service and adjustments. A special tool is required to check

for proper alignment.

DRIVE BELT CONDITION

Periodically check the condition and tension of the drive belt. Inspect the belt for

signs of excessive wear (frayed edges, missing cogs, cracks) and excessive

looseness. Replace the belt if any of these conditions exist. See page 207.

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.

DRIVE BELT DEFLECTION

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).

DRIVE BELT DEFLECTION ADJUSTMENT

To adjust the drive belt, do the following:

1. Loosen the driven clutch set screw with 7/16 wrench

2. Using an 1/8" allen wrench, adjust set screw until belt deflection meets

specification

3. Holding set screw with allen wrench, lightly tighten nut

4. Using the L wrench, open driven clutch sheaves 0.5 in.

5. Tighten deflection screw nut to specification

TORQUE

145 in-lbs

6. Rotate belt clockwise while removing L wrench

122

MAINTENANCE

DRIVE BELT REMOVAL

NOTICE

Do not attempt to remove the drive belt after operating in reverse. The

snowmobile must be stopped after forward motion to prevent damage to

components during belt removal. Rotate the driven clutch counter-clockwise 1/

4 turn by hand to ensure forward engagement before attempting to remove the

belt.

1. Stop the engine after operating in a forward motion.

2. Turn the ignition key off. Wait for the engine to come to a complete stop.

3. Lock the parking brake.

4. Remove the left side panel.

5. Rotate the driven clutch counter-clockwise 1/4 turn by hand to ensure

forward engagement.

6. Locate the L-wrench in the tool kit. Install the wrench into the open threaded

hole in the outer sheave of the clutch.

7. Turn the wrench clockwise until the sheaves open far enough to remove the

belt. If the wrench does not turn readily, rotate the driven clutch counter-

clockwise an additional 1/4 turn by hand and try again.

8. Remove the belt from the driven clutch.

DRIVE BELT INSTALLATION

1. With the L-wrench inserted into the threaded hole and the sheaves in the

open position, install the drive belt.

TIP

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.

2. Rotate the belt clockwise to remove slack while removing the L-wrench.

3. Reinstall the side panel.

4. Break in the new belt. See page 92.

123

MAINTENANCE

TRACK MAINTENANCE

WARNING

Moving parts can cut and crush body parts. When performing the checks and

adjustments recommended on the following pages, stay clear of all moving

parts. Never perform track measurement or adjustments with the engine

running.

TRACK INSPECTION

WARNING

Broken track rods can cause a rotating track to come off the snowmobile,

which could cause serious injury or death. Never operate with a damaged

track. Never rotate a damaged track under power.

NOTE

The figures below are for reference only. Your model may differ slightly.

1. Using a hoist, safely lift and support

the rear of the snowmobile off the

ground.

2. Rotate the track by hand to check for

damage.

3. Carefully examine the track along

the entire length of each rod

Bend the track to check for

breakage.

4. Replace the track if any rod damage

is found.

124

MAINTENANCE

TRACK LUBRICATION

The slide rail needs snow for lubrication. Excessive wear indicates insufficient

lubrication. A new rail slide can cause faster heat build-up in limited lubrication,

resulting in excessive wear.

WARNING

Operating with insufficient lubrication between the rail slide and track guide

clips can cause track failure, loss of vehicle control and loss of braking ability,

which can result in serious injury or death. Avoid operating for extended

periods on ice and other surfaces that have little or no snow for lubrication.

If excessive rail slide wear occurs due to poor snow conditions, additional wheel

kits are available. Your 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 TENSION

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

TIP

Tension adjustments should be made only after the track is warmed up and

limber.

1. Turn the engine off.

2. Lift the rear of the snowmobile and safely support it off the ground.

3. Place the recommended weight or downward pressure on the track at the

specified distance (see chart) ahead of the center of the rear idler wheel.

4. Measure at the point where the weight is hanging.

5. 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:

125

MAINTENANCE

6. Loosen the rear idler shaft bolt.

7. Loosen the locknuts.

8. Tighten or loosen the track adjusting screws to provide equal adjustment on

both sides of the track.

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

TIP

Check more frequently when the snowmobile is new.

10. Start the engine and slowly rotate the track at least five revolutions. Let the

track come to a stop (do not apply brakes).

11. Check track alignment (see page 127) and adjust as necessary.

12. Tighten the locknuts.

13. Tighten the idler shaft bolt.

TORQUE

35 ft. lbs. (47.5 Nm)

126

MAINTENANCE

WARNING

Improper alignment or adjustment may cause loss of steering control, resulting

in serious injury or death. Do not attempt to change the ski alignment. Your

POLARIS dealer can assist.

FRONT SUSPENSION INSPECTION

WARNING

Improper fastener torque or front suspension component damage may cause

loss of steering control, resulting in serious injury or death. Your POLARIS

dealer can assist.

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.

Ski Bolt Nuts

Tie Rod End Nuts

Upper/Lower Control Arm Nuts (All)

Sway Bar Fasteners

Shock Mounting Fasteners

Lower Control Arm Spindle Nuts

Upper Control Arm Spindle Nuts

Ski Loop Rear Fasteners

Ski Loop Front Fasteners

Ski Skag Fasteners

128

MAINTENANCE

SKI ALIGNMENT

WARNING

Improper ski alignment or adjustment may cause loss of steering control,

resulting in serious injury or death. Do not attempt to change the ski alignment

or camber adjustment. Your POLARIS dealer can assist.

1. Place the handlebars in a straight-ahead position.

2. With only vehicle weight compressing the suspension, measure 10 inches

(25.4 cm) forward from the center of the ski mounting bolt (see in illustration

below). At this point, measure between the skis. This is measurement

3. Perform the same measurement rearward from the center of the ski

mounting bolt. This is measurement

4. The q

measurement should be 1/8 inch (3 mm) greater than the

measurement. If the skis are misaligned, your dealer can assist with

alignment correction as camber adjustment may also be affected.

129

MAINTENANCE

SKI SKAGS

WARNING

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.

TIP

Carbide skags must be replaced if any abnormal wear or chipping is found.

SKAG REPLACEMENT

1. Raise and support the front of the

snowmobile so the skis are

approximately 6 inches (15.2 cm)

from the ground.

2. Remove the attaching nuts and pry

the skag q

downward.

3. Remove the front end of the skag.

4. Remove the rear end of the skag.

5. Reverse the steps to install a skag.

130

MAINTENANCE

RAIL SLIDE WEAR INSPECTION

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

to indicate the minimum permissible slide thickness

q. 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.

131

MAINTENANCE

BATTERY MAINTENANCE

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.

WARNING

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.

WARNING

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.

• Flush with water for 15 minutes and get prompt medical attention.Eyes:

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.

BATTERY REMOVAL

WARNING

Improperly connecting or disconnecting battery cables can result in an

explosion and cause serious injury or death. When removing the battery,

always disconnect the negative (black) cable first. When reinstalling the

battery, always connect the negative (black) cable last.

132

MAINTENANCE

1. Remove the right side panel to access the battery.

2. Remove the two plastic rivets

securing the console panel to the chassis.

3. Remove the plastic rivet

securing the fender to the chassis.

4. Disconnect the black (negative) battery cable first.

5. Disconnect the red (positive) battery cable last.

6. Remove the battery hold-down strap.

133

MAINTENANCE

7. Remove the battery shield

8. Remove the battery from the battery bracket.

BATTERY INSTALLATION (600/800 MODELS)

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.

1. Ensure that the battery is fully charged.

2. Set the battery in the battery holder.

3. Place the battery shield on the battery bracket. Install the screw to secure the

shield.

TORQUE

7 ft-lbs (10 Nm)

4. Install the battery hold-down strap.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

CAUTION

Verify the battery cables and wiring harness do not come into contact with the

brake disc. Move the wiring harness/cables behind the chassis tube and away

from the brake disc.

134

MAINTENANCE

7. Route the BROWN harness ground wires

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

and that the right fender

is pulled away

from the chassis. Item

is the constant power fuse connector.

8. Verify that cables are properly routed.

NOTICE

Ensure that the battery wires are routed in such a way that they cannot come

into contact with the brake disc.

9. Secure the right fender using the plastic rivet.

10. Reinstall the console using the two plastic rivets.

11. Reinstall the side panel.

BATTERY INSTALLATION (850 MODELS)

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.

135

MAINTENANCE

1. Ensure that the battery is fully charged.

2. Set the battery in the battery holder.

3. Place the battery shield on the battery bracket.

4. Install the battery hold-down strap.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

CAUTION

Verify the battery cables and wiring harness do not come into contact with the

brake disc. Move the wiring harness/cables behind the chassis tube and away

from the brake disc.

7. Route the BROWN harness ground wires

and BLACK main battery

ground cable

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

and that the right fender is pulled away

from the chassis. Item

is the constant power fuse connector.

8. Verify that cables are properly routed.

NOTICE

Ensure that the battery wires are routed in such a way that they cannot come

into contact with the brake disc.

136

MAINTENANCE

9. Secure the right fender using the plastic rivet.

10. Reinstall the console using the two plastic rivets. Reinstall the side panel.

BATTERY IDENTIFICATION

IMPORTANT

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.

LEAD ACID CONVENTIONAL / DRY SHIPPED AGM

BATTERY

• 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)

LOW MAINTENANCE BATTERY

• 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

137

MAINTENANCE

BATTERY CHARGING

To ensure your battery maintains its level of charge, the battery should be

connected to a battery tender/trickle charger using the battery tender port

1. Check the battery voltage with a

voltmeter or multimeter. A fully

charged battery will register 12.8 V

or higher.

2. If the voltage is less than 12.8 volts,

recharge the battery at 1.2 amps or

less until the battery voltage is 12.8

or greater using the battery tender

port q.

RESTRICTION

When using an automatic charger, refer to the charger manufacturer's

instructions for recharging. When using a constant current charger, use the

following guidelines for recharging.

WARNING

An overheated battery may explode, causing severe injury or death. Always

watch charging times carefully. Stop charging if the battery becomes very

warm to the touch. Allow it to cool before resuming charging.

TIP

Always verify battery condition before and 1-2 hours after the end of charging.

138

MAINTENANCE

SPECIFIC GRAVITY OF

ELECTROLYTE FREEZING POINT

1.200 -17° F

1.150 +5° F

1.100 +18° F

1.050 +27° F

LEAD ACID CONVENTIONAL BATTERY

MAINTENANCE

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.

CAUTION

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.

DRY SHIPPED AGM BATTERY MAINTENANCE

CAUTION

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.

LEAD ACID LOW MAINTENANCE BATTERY

MAINTENANCE

Recharge the battery to its full capacity every 30 to 60 days.

140

MAINTENANCE

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.

CAUTION

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.

AGM LOW MAINTENANCE BATTERY

MAINTENANCE

CAUTION

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.

TRANSPORTING THE SNOWMOBILE

Whenever the snowmobile is transported:

1. Be sure the fuel cap and oil cap are installed correctly.

2. Tie the snowmobile to the transporting unit securely using suitable straps.

3. Remove the ignition key to prevent loss.

NOTE

Use of a cover is recommended when transporting your vehicle on an open

trailer or sled deck.

141

MAINTENANCE

SUMMER STORAGE GUIDE

TREATING THE FUEL SYSTEM

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:

1. The rider should consume as much fuel in the fuel tank as possible during

the last rides of the season.

2. 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.

3. 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.

4. Position the snowmobile outside in a well-ventilated area.

5. Start and run the engine for 10-15 minutes to distribute the treated fuel

throughout the fuel system.

NOTICE

On Carbureted engines (550cc / 120 Youth), run the engine for 10-15 minutes

and then turn the fuel shut off valve to ‘OFF’. Continue to run the engine until

the engine stalls and turns off. Doing this drains the carburetors of fuel.

FOGGING THE ENGINE

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:

142

MAINTENANCE

1. Remove the spark plugs from the engine.

2. 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.

3. Loosely install the spark plugs.

NOTICE

Do not install new spark plugs after fogging the cylinders. Fogging oil prevents

the formation of rust / corrosion by sticking to the internal engine components –

including the spark plug electrodes. Replace these spark plugs the following

season after all of the fogging oil has been burned out of the engine.

DRIVE BELT STORAGE

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:

1. Remove the primary and secondary drive belt from the snowmobile.

2. Inspect the drive belt for wear and glazing. Compare the primary belt with the

back-up (secondary) belt. Decide if a new belt is needed next season and

note the primary belt can now be used as the back-up belt next season.

3. Clean the driven and driven clutch sheaves with Isopropyl Alcohol. Allow the

alcohol to air dry. Continue cleaning the sheave faces until all belt residue is

removed.

BATTERY/ELECTRICAL SYSTEM STORAGE

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 tender/trickle

charger using the battery tender port

143

MAINTENANCE

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 tender. In addition, removing the battery allows access to other

maintenance items, such as the chaincase chain tensioner bolt.

2. Connect a Polaris battery tender or equivalent commercially available tender

to the battery.

3. 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.

CHAINCASE

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.

1. Follow the Owner’s Manual procedures and drain / fill the chaincase with

new Polaris SCL (Synthetic Chaincase Lubricant). All Polaris PRO-RIDE and

AXYS snowmobile feature ‘fill-to-spill’ lubricant fill specifications which

makes it relatively ‘easy’ to re-fill the chaincase.

2. 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.

3. Loosen the drive chain adjuster lock nut. Turn the adjuster screw inwards

until it can no longer be turned by hand.

4. At this point, turn the adjuster nut ¼ turn counter clockwise.

5. Tighten and then torque the jam nut to the specification listed in the Owner’s

Manual. Release the parking brake.

NOTE

If the snowmobile is equipped with a transmission (Titan / WideTrak

snowmobiles), there is not a drive chain adjustment procedure.

CLEANING THE SNOWMOBILE

Snowmobiles, especially those transported on sled decks and open trailers can

accumulate allot of water and road dirt / salt during the riding season. The

snowmobile must be thoroughly washed and cleaned to prevent corrosion and

rust formation.

144

MAINTENANCE

1. Wash the snowmobile with a garden hose and a solution of soapy 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.

2. Dry the snowmobile with a lint-free towel. Allow the entire snowmobile to air

dry afterwards.

3. Clean the engine compartment. Use a shop vacuum if required to remove

dirt, leaves, cat tails, etc. from within the engine compartment.

4. Hand wash the exhaust system and dry the pipe and silencer with a clean

shop towel.

5. Apply “spray” metal protectant on exposed metal components, such as the

exhaust pipe, silencer, shock shafts, and suspension springs / pivots.

IMPORTANT

Do not spray metal protectant on the drive or driven clutches.

LUBRICATE THE 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.

1. 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.

2. Pump fresh grease into all zerks until the grease can be seen purging out of

each joint.

3. Use a paper towel to clean up and remove all of the residual purged grease

from the joints.

STORING THE SNOWMOBILE

Never store the snowmobile in a hot, humid location if possible. Try to store the

snowmobile away from direct sunlight.

1. Cover the snowmobile with a Polaris cover or after-market equivalent cover.

2. Store in a location always 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.

145

MAINTENANCE

WINTER RIDE PREPARATION

Preparing a snowmobile for in-season service is basically performing some of

the summer storage procedures in reverse order.

1. 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.

2. 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.

3. If the snowmobile is equipped with electric start or a PIDD on-board battery,

remove the battery from the battery tender and re-install it back into the

battery box. Follow the owner’s manual for battery installation procedures.

4. Verify the spark plugs are installed and torqued. Re-install the spark plug

wires.

NOTE

Verify you hear an audible “click” when pushing the spark plug caps down onto

the spark plugs. This ensures the plug caps are seated properly.

5. If you placed dryer sheets inside the engine compartment, remove them.

6. Using clean and dry shop towel, wipe down the exhaust pipe , silencer, and

clutch sheaves.

7. Install the primary drive belt onto the clutches with the “Polaris” writing

readable from the outside of the snowmobile.

8. Install the back-up (secondary) drive belt into the belt holder.

9. On the carbureted snowmobiles, turn the fuel shut-off valve to the ON

position.

10. With the track suspended up, off the ground, follow the track tension

adjustment procedure as outlined in your owner’s manual.

11. Start and run the engine. Allow the engine to run for at least 15 minutes.

Occasionally “blip” the throttle to rev the engine.

NOTE

The exhausted may emit more smoke than usual as the fogging oil is burned

out of the engine.

12. 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.

146

MAINTENANCE

13. Turn off the engine. If the track requires, re-align the track at this time.

14. After adjusting the track or allowing the engine to cool down. Add coolant to

reservoir bottle if required.

15. Re-start the engine and allow it ti run for another 15 minutes. After 15

Minutes, shutoff the engine and allow the exhaust pipe to cool.

16. 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.

17. Inspect the ski wear bars/carbides. Now is the time to replace the wear bars

if damage if found or carbides are worn.

18. Add Carbon Clean to the fuel tank.

19. Log onto www.ridecommand.com and download the latest TRAILS PIDD

update files. Update the PIDD (if equipped) with the latest TRAILS update

file.

20. 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.

147

MAINTENANCE

148

SPECIFICATIONS

600 SWITCHBACK ASSAULT

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (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 qts. (3.7 l)

Height 54.5 inches (138.4 cm)

Length 125 inches (317.5 cm)

Designed Width 47 inches (119 cm)

Brake Type Hayes Phantom Floating Piston DOT 4

Drive Clutch Center Distance 10.625 inches (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 S6011-6044-LP6P

Displacement 599 cc

Cylinders 2

Bore x Stroke (mm) 77.25 x 64

Alternator Output 400 watt

Throttle Body 1204920

Recommended Engine Oil VES

149

SPECIFICATIONS

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

(ELEC-

TRIC

START)

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.

0-600 (0-2000)

10-64

(132158-

140/330

(7043829)

Blk/Purple

(7043363)

48/42–.36

(5140312)

22:41-70

1.352 Cobra

20:39-68

1.6 Cobra

19:40-68

2.0” Series 4

600-1200 (2000-

4000)

10-62

(132158-

1200-1800 (4000-

6000)

10-60

(132158-

1800-2400 (6000-

8000)

10-58

(132158-

2400-3000 (8000-

10,000)

10-56

(132168-

3000-3600

(10,000-12,000)

10A-L

(132153-

150

SPECIFICATIONS

600 RMK 144

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (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 qts. (3.7 l)

Height 48.5 inches (123.2 cm)

Length 125 inches (317.5 cm)

Designed Width 46.5 inches (118 cm)

Brake Type Hayes Phantom

Drive Clutch Center Distance 10.625 inches (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 S6011-6044-LP6P

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

151

SPECIFICATIONS

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

(132158-

140/330

(7043829)

BLK/

PURPLE

(7043363)

STR 40 LW

(5140109) 19:40–68

450-900 (1500-

3000)

10-62

(132158-

900-1500 (3000-

5000)

10-60

(132158-

1500-2100 (5000-

7000)

10-58

(132158-

2100-2700

(70000-9,000)

10-56

(132168-

2700-3350 (9000-

11,000)

10-54

(132168-

152

SPECIFICATIONS

600 VOYAGEUR

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (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 qts. (3.7 l)

Height 48.5 inches (123.2 cm)

Length 127 inches (322.6 cm)

Designed Width 46.5 inches (118 cm)

Brake Type Hayes Phantom

Drive Clutch Center Distance 10.625 inches (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 S6011-6044-LP6P

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

153

SPECIFICATIONS

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.

0-600 (0-2000)

10-64

(132158-

140/330

(7043829)

BLK/PUR

7043363

48/42.36

(5140312) 19:40-68

600-1200 (2000-

4000)

10-62

(132158-

1200-1800 (4000-

6000)

10-60

(132158-

1800-2400 (6000-

8000)

10-58

(132158-

2400-3000 (8000-

10,000)

10-56

(132168-

3000-3600

(10,000-12,000)

10–54

(132168-

154

SPECIFICATIONS

600 INDY SP/XC/XCR 129

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (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 qts. (3.7 l)

Height 46 inches (116.8 cm)

Length 117 inches (297.2 cm)

Designed Width 47 inches (119.4 cm)

Brake Type AXYS™ Radial

Drive Clutch Center Distance 10.625 inches (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 S6011-6044-LP6P

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

155

SPECIFICATIONS

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

(ELECTRIC

START)

CLUTCH

SPRING

DRIVEN

HELIX GEARING

0-600

(0-2000)

10-64

(132158-

Black

140/330

(7043829)

Black/Purple

160/240

(7043363)

48/42/.36

BA35

(5140312)

22/41/70P

1.25" Ice

Ripper XT

1.352"

Cobra

20/39/68P

1.5" Storm

1.75"

Backcountry

600-1200

(2000-4000)

10-62

(132158-

1200-1800

(4000-6000)

10-60

(132158-

1800-2400

(6000-8000)

10-58

(132158-

2400-3000

(8000-10,000)

10-56

(132168-

21/42/70P

1.25" Ice

Ripper XT

1.352"

Cobra

19/40/68P

1.5" Storm

1.75"

Backcountry

3000-3600

(10,000-12,000)

10 AL

(132153-

Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)

Re-torque after running engine.

OPTIONAL-USE 2 GRAM LIGHTER CLUTCH WEIGHTS WHEN OPERATING IN

PROLONGED WARM TEMPERATURES (LATE FALL/SPRING SEASON) TO

MAINTAIN PEAK OPERATING RPM.

156

SPECIFICATIONS

600 INDY SP/XC/ADVENTURE 137

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (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 qts. (3.7 l)

Height 46 inches (116.8 cm)

Length 120 inches (305 cm)

Designed Width 47 inches (119.4 cm)

Brake Type Hayes Phantom Floating Piston DOT 4

Drive Clutch Center Distance 10.625 inches (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 S6011-6044-LP6P

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

157

SPECIFICATIONS

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

(ELECTRIC

START)

CLUTCH

SPRING

DRIVEN

HELIX GEARING

0-600

(0-2000)

10-64

(132158-

Black

140/330

(7043829)

Black/Purple

160/240

(7043363)

48/42/.36

BA35

(5140312)

22/41/70P

1.25" RIP II

1.352"

Cobra

1.25” Ice Rip

20/39/68P

1.5" Storm

600-1200

(2000-4000)

10-62

(132158-

1200-1800

(4000-6000)

10-60

(132158-

1800-2400

(6000-8000)

10-58

(132158-

2400-3000

(8000-10,000)

10-56

(132168-

3000-3600

(10,000-12,000)

10 AL

(132153-

Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)

Re-torque after running engine.

OPTIONAL-USE 2 GRAM LIGHTER CLUTCH WEIGHTS WHEN OPERATING IN

PROLONGED WARM TEMPERATURES (LATE FALL/SPRING SEASON) TO

MAINTAIN PEAK OPERATING RPM.

158

SPECIFICATIONS

800 SWITCHBACK ASSAULT

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (3.8 l)

Chaincase Oil Capacity 10oz. (296 ml)

Fuel Tank Capacity 12 gal. (45.4 l)

Gearcase Oil Capacity N/A

Oil Capacity (qts./l) 3.9 qts. (3.7 l)

Height 54.5 inches (138.4 cm)

Length 125 inches (317.5 cm)

Designed Width 47 inches (119 cm)

Brake Type Hayes Phantom Floating Piston DOT 4

Drive Clutch Center Distance 10.625 inches (27 cm)

Drive Belt P/N 3211177

Drive Clutch P-85

Driven Clutch Lightweight Team Roller Reverse

Reverse Transmission Electronic Reverse

ENGINE AND COOLING

Engine ASM-ENG S6012-8044-LP8P

Displacement 794 cc

Cylinders 2

Bore x Stroke (mm) 85 x 70

Alternator Output 400 watt

Throttle Body 1205241

Recommended Engine Oil VES

Throttle Body Bore Size 48 mm

159

SPECIFICATIONS

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 BPR 9ES /.027 inches (0.7 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.

0-600 (0-2000)

10-68

(132242-

110-290

(7042287)

BLU/BLK

(7043064) 58/44/.36

(5140311)

23:40-70

1.352 Cobra

22:41-70

1.6 Cobra

19:40-68

2.0” Series 4

600-1200 (2000-

4000)

10-66

(132158-

1200-1800 (4000-

6000)

10-64

(132158-

1800-2400 (6000-

8000) 10-62

(132158-

6) BLK

(7043063)

2400-3000 (8000-

10,000) 120-320

(7044537)

STR 40LW

(5140109)

19:40-68

1.352 Cobra

1.6 Cobra

2.0” Series 4

3000-3600

(10,000-12,000)

10-60

(132158-

* = STOCK INTERNATIONAL

160

SPECIFICATIONS

800 SKS 146

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (3.8 l)

Chaincase Oil Capacity 10oz. (296 ml)

Fuel Tank Capacity 12 gal. (45.4 l)

Gearcase Oil Capacity N/A

Oil Capacity (qts./l) 3.9 qts. (3.7 l)

Height 51 inches (129.5 cm)

Length 125 inches (317.5 cm)

Designed Width 46.5 inches (118 cm)

Brake Type Hayes Phantom Floating Piston DOT 4

Drive Clutch Center Distance 10.625 inches (27 cm)

Drive Belt P/N 3211177

Drive Clutch P-85

Driven Clutch Lightweight Team Roller Reverse

Reverse Transmission Electronic Reverse

ENGINE AND COOLING

Engine ASM-ENG S6012-8044-LP8P

Displacement 794 cc

Cylinders 2

Bore x Stroke (mm) 85 x 70

Alternator Output 400 watt

Throttle Body 1205241

Recommended Engine Oil VES

Throttle Body Bore Size 48 mm

Idle RPM 1700 +/- 200

161

SPECIFICATIONS

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 BPR 9ES /.027 inches (0.7 mm)

Recommended Fuel Octane 91 recommended (87 minimum)

CLUTCHING CHART

ALTITUDE

Meters

(Feet)

Drive

Clutch

Shift

Weight

Drive Clutch

Spring

Driven Clutch

Spring

Driven Helix Chaincase

Gearing/

Pitch

0-600

(0-2000)

10-70

(1322414)

120/320

(7044537)

BLACK

(7043063)

STR 40 LW

(5140109) 19:40 70P

600-1200

(2000-

4000)

10-68

(1322427)

1200-1800

(4000-

6000)

10-66

(11321584)

1800-2400

(6000-

8000)

10-64

(1321585)

2400-3000

(8000-

10000)

10-62

(1321586)

3000-3600

(10000-

12000)

10-60

(1321587)

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.

162

SPECIFICATIONS

800 INDY XC/XCR 129

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (3.8 l)

Chaincase Oil Capacity 10oz. (296 ml)

Fuel Tank Capacity 12 gal. (45.4 l)

Gearcase Oil Capacity N/A

Oil Capacity (qts./l) 3.9 qts. (3.7 l)

Height 46 inches (116.8 cm)

Length 117 inches (297.2 cm)

Designed Width 47 inches (119.4 cm)

Brake Type Hayes Phantom Floating Piston DOT 4

Drive Clutch Center Distance 10.625 inches (27 cm)

Drive Belt P/N 3211177

Drive Clutch P-85

Driven Clutch Lightweight Team Roller Reverse

Reverse Transmission Electronic Reverse

ENGINE AND COOLING

Engine ASM-ENG S6012-8044-LP8P

Displacement 794 cc

Cylinders 2

Bore x Stroke (mm) 85 x 70

Alternator Output 400 watt

Throttle Body 1205241

Recommended Engine Oil VES

Throttle Body Bore Size 46 mm

163

SPECIFICATIONS

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 BPR 9ES /.027 inches (0.7 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.

0-600 (0-2000) 10-68

110-290

(7042287)

BLU/BLK

120-200

(7043064)

58/44/.36

(5140311)

23:37-68

1.25” ICE II

1.352”

Cobra

22:41-70

1.5” Storm

600-1200 (2000-

4000) 10-66

1200-1800 (4000-

6000) 10-64

1800-2400 (6000-

8000)

10-62

BLK

155-222

(7043063)

2400-3000 (8000-

10,000) Black

140-330

(7043829)

21:42-68

1.25” ICE II

1.352” Cobra

22:41-70

1.75”

Backcountry

3000-3600

(10,000-12,000) 10-60

*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.

164

SPECIFICATIONS

800 INDY XC/ADVENTURE 137

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (3.8 l)

Chaincase Oil Capacity 10oz. (296 ml)

Fuel Tank Capacity 12 gal. (45.4 l)

Gearcase Oil Capacity N/A

Oil Capacity (qts./l) 3.9 qts. (3.7 l)

Height 46 inches (116.8 cm)

Length 120 inches (305 cm)

Designed Width 47 inches (119.4 cm)

Brake Type Hayes Phantom Floating Piston DOT 4

Drive Clutch Center Distance 10.625 inches (27 cm)

Drive Belt P/N 3211177

Drive Clutch P-85

Driven Clutch Lightweight Team Roller Reverse

Reverse Transmission Electronic Reverse

ENGINE AND COOLING

Engine ASM-ENG S6012-8044-LP8P

Displacement 795 cc

Cylinders 2

Bore x Stroke (mm) 85 x 70

Alternator Output 400 watt

Throttle Body 1205241

Recommended Engine Oil VES

Throttle Body Bore Size 46 mm

165

SPECIFICATIONS

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 BPR 9ES /.027 inches (0.7 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.

0-600 (0-2000)

10-68

(132242-

110-290

(7042287)

Blue/Black

120-200

(7043064)

58/44/.36

(5140311)

23:37-68

1.25” ICE

RIP

22:37–68

1.352”

Cobra

22:41-70

1.5” Storm

600-1200 (2000-

4000)

10-66

(132158-

1200-1800 (4000-

6000)

10-64

(132158-

1800-2400 (6000-

8000) 10-62

(132158-

6) Black

155-222

(7043063)

2400-3000 (8000-

10,000) Black

140-330

(7043829)

3000-3600

(10,000-12,000)

10-60

(132158-

*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.

166

SPECIFICATIONS

850 SWITCHBACK ASSAULT 144

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (3.8 l)

Chaincase Oil Capacity 10oz. (296 ml)

Fuel Tank Capacity 12 gal. (45.4 l)

Gearcase Oil Capacity N/A

Oil Capacity (qts./l) 3.9 qts. (3.7 l)

Height 54.5 inches (138.4 cm)

Length 125 inches (317.5 cm)

Designed Width 47 inches (119 cm)

Brake Type Hayes Phantom Floating Piston DOT 4

Drive Clutch Center Distance 10.625 inches (27 cm)

Drive Belt P/N 3211215

Drive Clutch P-85

Driven Clutch Lightweight Team Roller Reverse

Reverse Transmission Electronic Reverse

ENGINE AND COOLING

Engine ASM-ENG S6032-8444-LP8R

Displacement 840 cc

Cylinders 2 Monoblock

Bore x Stroke (mm) 85 x 74

Alternator Output 500 watt @ 5000 RPM

Throttle Body 1205875

Oil Injection Electronic Oil Pump

Recommended Engine Oil VES

167

SPECIFICATIONS

Throttle Body Bore Size 50 mm

Idle RPM 1800 +/- 200

Rated Operating RPM 8250 +0/- 150

Cooling Liquid

Thermostat Opening Temp. 120°F (49°C)

Ignition Type Multi-Dimensional CDI

Spark Plug / Gap NGK BPR 9ES /.027 inches (0.7 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.

0-600 (0-2000)

10-72

(132242-

Black

110-290

(7042287)

BLU/RED

(7043057)

58/44/.36

(5140311)

23:40-70

1.352 Cobra

22:41-70

1.6 Cobra

19:40-68

2.0” Series 4

600-1200 (2000-

4000)

10-70

(132241-

1200-1800 (4000-

6000) 10-68

(132242-

1800-2400 (6000-

8000)

BLK

(7043063)

2400-3000 (8000-

10,000)

10-66

(113215 -

84) 120-320

(7044537)

19:40-68

1.352 Cobra

1.6 Cobra

2.0” Series 4

3000-3600

(10,000-12,000)

10-64

(132158-

* = STOCK INTERNATIONAL

168

SPECIFICATIONS

850 SKS 146

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (3.8 l)

Chaincase Oil Capacity 10oz. (296 ml)

Fuel Tank Capacity 12 gal. (45.4 l)

Gearcase Oil Capacity N/A

Oil Capacity (qts./l) 3.9 qts. (3.7 l)

Height 51 inches (129.5 cm)

Length 125 inches (317.5 cm)

Designed Width 46.5 inches (118 cm)

Brake Type Hayes Phantom Floating Piston DOT 4

Drive Clutch Center Distance 10.625 inches (27 cm)

Drive Belt P/N 3211215

Drive Clutch P-85

Driven Clutch Lightweight Team Roller Reverse

Reverse Transmission Electronic Reverse

ENGINE AND COOLING

Engine S5836-8444-ON8R

Displacement 840 cc

Cylinders 2 Monoblock

Bore x Stroke (mm) 85 x 74

Alternator Output 500 watt @ 5000 RPM

Throttle Body 1205875

Oil Injection Electronic Oil Pump

Recommended Engine Oil VES

169

SPECIFICATIONS

Throttle Body Bore Size 50 mm

Idle RPM 1800 +/- 200

Rated Operating RPM 8250 +0/- 150

Cooling Liquid

Thermostat Opening Temp. 120°F (49°C)

Ignition Type Multi-Dimensional CDI

Spark Plug / Gap NGK BPR 9ES /.027 inches (0.7 mm)

Recommended Fuel Octane 91 recommended (87 minimum)

DOMESTIC MODELS

CLUTCH SETTINGS

ALTITUDE

meters (feet)

DRIVE CLUTCH DRIVEN CLUTCH

Shift

Weight

Clutch

Spring

Clutch

Spring

Driven

Helix Gearing

0-900 (0-3000) 10-72

(1322428)

120/320

(70445-

37)

Red/Blue

(7043057)

60/44/.36

(5143262)

19:40 70P

2.25

Series 5.2

900-1500 (3000-

5000)

10-70

(1322414)

1500-2100

(5000-7000)

10-68

(1322427)

2100-2700

(7000-9000)

10-66

(1321584)

2700-3300

(9000-11000)

10-64

(1321585)

3300-3900

(11000-13000)

10-62

(1321586)

* 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.

170

SPECIFICATIONS

INTERNATIONAL MODELS

CLUTCH SETTINGS

ALTITUDE

meters (feet)

DRIVE CLUTCH DRIVEN CLUTCH

Shift

Weight

Clutch

Spring

Clutch

Spring

Driven

Helix Gearing

0-900 (0-3000) 10-72

(1322428)

Almond/

Blue

(70419-

22)

Red/Blue

(7043057)

60/44/.36

(5143262)

19:40 70P

2.25

Series 5.2

900-1500 (3000-

5000)

10-70

(1322414)

1500-2100

(5000-7000)

10-68

(1322427)

2100-2700

(7000-9000)

10-66

(1321584)

2700-3300

(9000-11000)

10-64

(1321585)

3300-3900

(11000-13000)

10-62

(1321586)

* 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.

850 INDY XC/XCR 129

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (3.8 l)

Chaincase Oil Capacity 10oz. (296 ml)

Fuel Tank Capacity 12 gal. (45.4 l)

Gearcase Oil Capacity N/A

Oil Capacity (qts./l) 3.9 qts. (3.7 l)

Height 46 inches (116.8 cm)

Length 117 inches (297.2 cm)

171

SPECIFICATIONS

Designed Width 47 inches (119 cm)

Brake Type Hayes Phantom Floating Piston DOT 4

Drive Clutch Center Distance 10.625 inches (27 cm)

Drive Belt P/N 3211215

Drive Clutch P-85

Driven Clutch Lightweight Team Roller Reverse

Reverse Transmission Electronic Reverse

ENGINE AND COOLING

Engine ASM-ENG S6032-8444-LP8R

Displacement 840 cc

Cylinders 2

Bore x Stroke (mm) 85 x 74

Alternator Output 700 watt

Throttle Body 1205875

Recommended Engine Oil VES

Throttle Body Bore Size 50 mm

Idle RPM 1800 +/- 200

Rated Operating RPM 8250 +0/- 150

Cooling Liquid

Ignition Type CDI

Ignition Timing °BTDC 18° @ idle, 1700 RPM w/120°F (49°C)

water temp

Spark Plug / Gap NGK BPR9ES / .027 inches (0.7 mm)

Recommended Fuel Octane 91 recommended (87 minimum)

172

SPECIFICATIONS

850 INDY XC/ADVENTURE 137

CAPACITIES AND DIMENSIONS

Body Style AXYS

Rider Capacity 1

Coolant Capacity 4 qts. (3.8 l)

Chaincase Oil Capacity 10oz. (296 ml)

Fuel Tank Capacity 12 gal. (45.4 l)

Gearcase Oil Capacity N/A

Oil Capacity (qts./l) 3.9 qts. (3.7 l)

Height 46 inches (116.8 cm)

Length 120 inches (305 cm)

Designed Width 47 inches (119 cm)

Brake Type Hayes Phantom Floating Piston DOT 4

Drive Clutch Center Distance 10.625 inches (27 cm)

Drive Belt P/N 3211215

Drive Clutch P-85

Driven Clutch Lightweight Team Roller Reverse

Reverse Transmission Electronic Reverse

ENGINE AND COOLING

Engine ASM-ENG S6032-8444-LP8R

Displacement 840 cc

Cylinders 2

Bore x Stroke (mm) 85 x 74

Alternator Output 700 watt

Throttle Body 1205875

Recommended Engine Oil VES

Throttle Body Bore Size 50 mm

174

SPECIFICATIONS

Idle RPM 1800 +/- 200

Rated Operating RPM 8250 +0/- 150

Cooling Liquid

Ignition Type CDI

Ignition Timing °BTDC 18° @ idle, 1700 RPM w/120°F (49°C)

water temp

Spark Plug / Gap NGK BPR9ES / .027 inches (0.7 mm)

Recommended Fuel Octane 91 recommended (87 minimum)

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.

0-600 (0-2000)

10-72

(132242-

BLACK

110-290

(7042287)

RED/BLU

140-200

(7043057)

58/44/.36

(5140311)

23:37-68

1.25” Ice

Ripper

1.352”

Cobra

22:41–70

1.5” Storm

600-1200 (2000-

4000)

10-70

(132241-

1200-1800 (4000-

6000) 10-68

(132242-

1800-2400 (6000-

8000)

120-320

(7044537)

BLK

155-222

(7043063)

2400-3000 (8000-

10,000)

10-66

(132158-

3000-3600

(10,000-12,000)

10-64

(132158-

* = STOCK INTERNATIONAL

175

SPECIFICATIONS

176

DIAGNOSTIC TROUBLE CODES (DTC)

DIAGNOSTIC TROUBLE CODES (DTCS) – 600/

800 MODELS

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

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

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.

177

DIAGNOSTIC TROUBLE CODES (DTC)

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

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

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.

178

DIAGNOSTIC TROUBLE CODES (DTC)

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

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

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.

179

DIAGNOSTIC TROUBLE CODES (DTC)

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

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

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

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

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.

180

DIAGNOSTIC TROUBLE CODES (DTC)

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

Knock (DET) Level

(PTO) 1353

0 P1337

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

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

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

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 /

181

DIAGNOSTIC TROUBLE CODES (DTC)

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

Connections, a Faulty Vehicle Speed

Sensor / Connections or Faulty ECU

/Connections.

Throttle Release

Signal 520194

3 P1555

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

(600 Only)

520215

5 P1477

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

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

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.

182

DIAGNOSTIC TROUBLE CODES (DTC)

DIAGNOSTIC TROUBLE CODES (DTCS) — 850

MODELS

DIAGNOSTIC TROUBLE CODES (DTCS)

SPN = SUSPECT PARAMETER NUMBER / FMI = FAILURE MODE INDICATOR

TROUBLE

CODE SPN FMI P-CODE FAULT CONDITION

Throttle

Position Sensor 51

3 P0123

Throttle

Position

Sensor 1

Voltage

High

This Trouble Code sets if the

Throttle Position Sensor Signal is

above 4.61 Volts. Can be caused

by Damaged Wiring, a faulty

Throttle Position Sensor or ECU /

Connections.

4 P0122

Throttle

Position

Sensor 1

Voltage

Low

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

TPS

Unrealis-

tic

Transition

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

Sensor 84 2 P0503

Vehicle

Speed

Sensor

Signal

Fault

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

Intake Air

Temperature

Sensor

105

3 P0113

Intake Air

Temp

Sensor

Circuit

Voltage

High

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

Intake Air

Temp

Sensor

Circuit

Voltage

Low

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

IAT

Sensor

Abnormal

Rate of

Change

This Trouble Code sets if the Intake

Air Temperature Sensor Signal

indicates an Unrealistic Rate of

Change. Can be caused by

Damaged Wiring, a faulty Intake Air

Temperature Sensor or ECU /

Connections.

184

DIAGNOSTIC TROUBLE CODES (DTC)

DIAGNOSTIC TROUBLE CODES (DTCS)

SPN = SUSPECT PARAMETER NUMBER / FMI = FAILURE MODE INDICATOR

TROUBLE

CODE SPN FMI P-CODE FAULT CONDITION

Barometric

Pressure

Sensor

108

3 P2229

Baromet-

ric

Sensor

Circuit

Voltage

High

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

Baromet-

ric

Sensor

Circuit

Voltage

Low

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.

Engine

Temperature

Sensor

110

0 P1217

Engine

Tempera-

ture

Over-

Temp

Shut-

down

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.

3 P0118

Engine

Tempera-

ture

Sensor

Circuit

Voltage

High

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

Engine

Tempera-

ture

Sensor

Circuit

Voltage

Low

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.

10 P0119

Engine

Tempera-

ture

Abnormal

Rate of

Change

This Trouble Code sets if the

Engine Temperature Sensor Signal

indicates an Unrealistic Rate of

Change.

Can be caused by Damaged

Wiring, a faulty Engine

Temperature Sensor or ECU /

Connections.

16 P0217

Engine

Over-

tempera -

ture Fault

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

185

DIAGNOSTIC TROUBLE CODES (DTC)

to overheat. This Trouble Code

Does Not indicate a problem with

the Engine Temperature Sensor.

Fuel Pressure

Sensor 157

3 P0193

Fuel Rail

Pressure

Sensor

Voltage

High

This trouble code sets if the Fuel

Pressure Sensor Voltage is above

4.85V. Can be caused by Damaged

Wiring, a faulty Fuel Pressure

Sensor or ECU / Connections.

4 P0192

Fuel Rail

Pressure

Sensor

Voltage

Low

This Trouble Code Sets if the Fuel

Pressure Sensor Circuit is below

0.1V. Can be caused by Damaged

Wiring, a faulty Fuel Pressure

Sensor or ECU / Connections.

18 P0196

Fuel Rail

Pressure

Below

Power

Limit

This Trouble Code Sets if the Fuel

Pressure drops below 3Bar

(43.5PSI) for 10 seconds. Can be

caused by a faulty Pump Flange

Assembly (PFA).

Fuel

Temperature

Sensor

174

3 P1322

Fuel

Tempera-

ture

Sensor

Voltage

High

This trouble code sets if the Fuel

Temperature Sensor Voltage is

above 4.81V. Can be caused by

Damaged Wiring, a faulty Fuel

Pressure Sensor or ECU /

Connections.

4 P1323

Fuel

Tempera-

ture

Sensor

Voltage

Low

This trouble code sets if the Fuel

Temperature Sensor Voltage is

Below 0.01V. Can be caused by

Damaged Wiring, a faulty Fuel

Pressure Sensor or ECU /

Connections.

Battery 158

3 P1567

Battery

Voltage

High

This Trouble Code Sets if the if the

Battery Voltage is above 15.0V Can

be caused by Damaged Wiring, a

faulty Battery or ECU / Connections

4 P1566

Battery

Voltage

Low

This Trouble Code Sets if the if the

Battery Voltage isBelow 10.0V Can

be caused by Damaged Wiring, a

faulty Battery or ECU / Connections

Pipe

Temperature

Sensor

173

0 P1517

Exhaust

Over-

Tempera-

ture

Shut-

down

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.

3 P0546

Exhaust

Temp

Sensor

Signal

High

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

186

DIAGNOSTIC TROUBLE CODES (DTC)

Wiring, a faulty Engine

Temperature Sensor or ECU /

Connections.

4 P0545

Exhaust

Temp

Sensor

Signal

Low

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.

10 P1546

Exhaust

Temp

Sensor

Unrealis-

tic

Transition

This Trouble Code sets if the

Exhaust Temperature Sensor

Signal changes Too Quickly to be

considered a Realistic Value. Can

be caused by Damaged Wiring, a

faulty Exhaust Temperature Sensor

or ECU / Connections.

Silencer

Temperature

Sensor

5201-

0 P1487

Exhaust

Tempera-

ture

Sensor 2

Tempera-

ture Too

High

This Trouble Code sets if the

Exhaust Temperature 2 Signal is

greater than 750C. Can be caused

by a Faulty Exhaust Temperature

Sensor/Connections or Lean Air/

Fuel Ratio causing high exhaust

temperature.

3 P1484

Exhaust

Tempera-

ture

Sensor 2

Voltage

High

This Trouble Code Sets if the if the

Exhaust Temp Sensor 2 Voltage is

above 4.96V. Can be caused by

Damaged Wiring, a faulty Exhaust

Temp Sensor or ECU / Connections

4 P1485

Exhaust

Tempera-

ture

Sensor 2

Voltage

Low

This Trouble Code Sets if the if the

Exhaust Temp Sensor 2 Voltage is

Below 0.06V. Can be caused by

Damaged Wiring, a faulty Exhaust

Temp Sensor or ECU / Connections

10 P1486

Exhaust

Tempera-

ture

Sensor 2

Abnormal

Rate of

Change

This Trouble Code sets if the

Exhaust Temperature Sensor

Signal changes Too Quickly to be

considered a Realistic Value. Can

be caused by Damaged Wiring, a

faulty Exhaust Temperature Sensor

or ECU / Connections.

14 P1488

Exhaust

Tempera-

ture

Sensor 2

Mismatch

with

Sensor 1

This Trouble Code Sets when

Exhaust Temperature Sensor 2

signal is 250C greater than Exhaust

Temp Sensor 1 signal. The

condition can be caused by

Damaged Wiring, faulty Exhaust

Temperature Sensor or ECU /

Connections.

187

DIAGNOSTIC TROUBLE CODES (DTC)

Gear Position

Sensor 523

2 P0914

Gear

Sensor

Signal

Circuit

Fault

This Trouble Code indicates the

Gear Switch Signal Voltage is

Outside an Acceptable Range. Can

be caused by Damaged Wiring or

Connectors in the Gear Switch

Circuit, a Damaged Switch,

Resistor Pack or Faulty ECU

/Connections.

3 P0917

Gear

Sensor

Signal

High

This Trouble Code indicates the

Gear Switch Signal Voltage is

Above the Maximum Acceptable

Voltage. Can be caused by

Damaged Wiring or Connectors in

the Gear Switch Circuit, a

Damaged Switch or Faulty ECU

/Connections.

4 P0916

Gear

Sensor

Signal

Low

This Trouble Code indicates the

Gear Switch Signal Voltage is

Below the Minimum Acceptable

Voltage. Can be caused by

Damaged Wiring or Connectors in

the Gear Switch Circuit, a

Damaged Switch or Faulty ECU

/Connections.

ECU Memory 628 13 P0601

ECU

Memory

Check-

sum Error

This Trouble Code Sets if an

Internal Memory Fault is detected in

the Engine Controller Can only be

caused by a defective ECU

Crank Position

Sensor 636

2 P0335

Crank-

shaft

Sensor

Signal

Fault

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.

8 P0336

Crank-

shaft

Position

Sensor

Circuit

Fault

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.

MAG Injector 651

3 P0262

MAG

Cylinder

Port

Injector

Short to B

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.

5 P0261

MAG

Cylinder

Port

Injector

Open

Circuit

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.

188

DIAGNOSTIC TROUBLE CODES (DTC)

PTO Injector 652

3 P0265

PTO

Cylinder

Port

Injector

Short to B

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.

5 P0264

PTO

Cylinder

Port

Injector

Open

Circuit

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.

Knock Sensor 731

2 P0325

Knock

Sensor

Plausibili-

ty Fault

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.

4 P0327

Knock

Sensor 1

Signal

Too Low

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.

MAG Ignition

Coil 1268 5 P1351

Ignition

Coil 1

(MAG)

Driver

Circuit

Open

This Trouble Code Sets if Ignition

Coil 1 (MAG) Driver Circuit is Open.

Can be caused by Damaged

Wiring/Connections, a Faulty MAG

Ignition Coil or ECU.

PTO Ignition

Coil 1269 5 P1352

Ignition

Coil 2

(PTO)

Driver

Circuit

Open

This Trouble Code Sets if Ignition

Coil 2 (PTO) Driver Circuit is Open.

Can be caused by Damaged

Wiring/Connections, a Faulty PTO

Ignition Coil or ECU.

MAG

Detonation 1352

0 P1336

Max.

Detona-

tion

Correc-

tion Limit

Reached,

MAG

Cylinder

This Trouble Code Sets if the

Engine Controller Reaches the

Maximum Detonation Control Limit

by Fuel Correction on the Mag

Cylinder Can be caused by

Incorrect Fuel (low octane or

Ethanol content), or Low Fuel

Pressure

16 P2336

Cylinder

1 (MAG)

Knock

Level

Critical

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.

189

DIAGNOSTIC TROUBLE CODES (DTC)

PTO

Detonation 1353

0 P1337

Max.

Detona-

tion

Correc -

tion Limit

Reached,

PTO

Cylinder

This Trouble Code Sets if the

Engine Controller Reaches the

Maximum Detonation Control Limit

by Fuel Correction on the PTO

Cylinder. Can be caused by

Incorrect Fuel (low octane or

Ethanol content), Low Fuel

Pressure or any other condition.

16 P2337

Cylinder

2 (PTO)

Knock

Level

Critical

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 3509 4 P06B1

Sensor

Supply

Voltage 1

Low

This Trouble Code sets if the

Sensor Supply 1 Voltage is below

an acceptable limit (approx. 4.50

Volts). Can be caused by Damaged

Wiring or Faulty/Shorted Sensors.

Sensor Supply

Voltage 2 3510 4 P06B4

Sensor

Supply

Voltage 2

Low

This Trouble Code sets if the

Sensor Supply 2 Voltage is below

an acceptable limit (approx. 4.50

Volts). Can be caused by Damaged

Wiring or Faulty/Shorted Sensors.

Sensor Supply

Voltage 3 3511 4 P16B6

Vehicle

Speed

Sensor

Supply

Voltage

Low

This Trouble Code sets if the

Sensor Supply 3 Voltage is below

an acceptable limit (approx. 4.5

Volts). Can be caused by Damaged

Wiring or Faulty Sensor/shorted to

ground.

Oil pump 3589

5 P16BA

Oil Pump

Driver

Circuit

Open

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

Oil Pump

Driver

Circuit

Fault

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

Injector Supply

Voltage 3598

3 P16A9

Injector

Output

Supply 2

Voltage

High

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

Injector

Output

Supply 2

Voltage

Low

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.

190

DIAGNOSTIC TROUBLE CODES (DTC)

PBR

32522

208 P1603

Regulator

Thermal

Shut-

down

This Trouble Code Sets if the

Regulator has entered thermal

shutdown. Can be caused by Long

periods of high load operation and

idle with a snow-covered hood

223 P1604

Regulator

Tempera-

ture

Warning

This Trouble Code Sets if the

Regulator has indicated a

temperature warning. Can be

caused by Long periods of high

load operation and idle with a snow-

covered hood

245 P1606

Regula-

tor: ECU

Open

Circuit

This Trouble Code Sets if the

Regulator has detected an Open

Circuit in the ECU Supply Can be

caused by a blown ECU Fuse or

Open Circuit in the ECU power

wiring.

246 P1607

Regula-

tor: ECU

Overload

This Trouble Code Sets if the

Regulator has detected Excessive

Current Draw in the ECU Supply

Can be caused by defective power

circuit to the ECU, electrical

modifications or faulty ECU

255 P1608

Regula-

tor: ECU

Voltage

Too High

This Trouble Code Sets if the

Regulator has detected Excessive

Voltage in the ECU Supply Can be

caused by damaged wiring,

Regulator connections or Regulator

32523

4 P1609

Regula-

tor:

Critical

Voltage

Too Low

This Trouble Code Sets if the

Regulator has detected Low

Voltage in the Critical Circuit Can

be caused by damaged Regulator

wiring or connections, electrical

modifications or faulty Regulator

5 P160B

Regula-

tor:

Critical

Open

Circuit

This Trouble Code Sets if the

Regulator has detected an Open

Circuit in the Critical Circuit Can be

caused by damaged wiring, faulty

headlight, Fuel Pump or Regulator

connections

6 P160C

Regula-

tor:

Critical

Short

Circuit

This Trouble Code Sets if the

Regulator has detected Excessive

Current in the Critical Circuit Can

be caused by damaged wiring,

faulty headlight, Fuel Pump or

Regulator connections

15 P160D

Regula-

tor:

Critical

Voltage

Too High

This Trouble Code Sets if the

Regulator has detected Excessive

Voltage in the Critical Circuit Can

be caused by damaged wiring,

faulty headlight, Fuel Pump or

Regulator connections

191

DIAGNOSTIC TROUBLE CODES (DTC)

20 P160E

Regula-

tor:

Chassis

Voltage

Too Low

This Trouble Code Sets if the

Regulator has detected Low

Voltage in the Chassis Circuit Can

be caused by damaged wiring or

faulty grip heaters

22 P160F

Regula-

tor:

Chassis

Short

Circuit

This Trouble Code Sets if the

Regulator has detected Excessive

Current Draw in the Chassis Circuit

Can be caused by damaged wiring

or faulty grip heaters

31 P1610

Regula-

tor:

Chassis

Voltage

Too High

This Trouble Code Sets if the

Regulator has detected Excessive

Voltage in the Chassis Circuit Can

be caused by damaged wiring,

Regulator connections or Regulator

32531

36 P1510

Regula-

tor: Stator

Output

Low

This Trouble Code Sets if the

Regulator has detected a Low

Voltage condition in the Stator Can

be caused by a Short to ground in

the Stator or damaged Stator

wiring.

37 P1511

Regula-

tor: Stator

Open

Circuit

This Trouble Code Sets if the

Regulator has detected an Open

Circuit condition in the Stator Can

be caused by an Open Circuit in the

Stator or damaged Stator wiring.

5203-

76 31 P1618

Regulator

Chassis

Voltage

Disabled

This Trouble Code Sets if the

Regulator has detected an internal

fault Can be caused by a faulty

Voltage Regulator Module

5203-

77 31 P1619

Regulator

ECU

Voltage

Too Low

This Trouble Code Sets if the

Regulator has detected an internal

Low Voltage Condition Can be

caused by damaged wiring/

connections or Regulator/

connections

5203-

78 31 P161A

Regulator

Reduced

Perform-

ance

This Trouble Code Sets if the

Regulator has detected an internal

fault Can be caused by a faulty

Voltage Regulator Module

5206-

60 31 P161B

Regulator

Near

Thermal

Shut-

down

This Trouble Code Sets if the

Regulator is near the thermal

shutdown point Can be caused by

excessive power consumption or

insufficient cooling air flow

ECU Voltage 5201-

74 3 P1341

ECU

Supply

Voltage

High

This Trouble Code sets if the ECU

Supply Voltage is above 17.00V

Can be based by faulty wiring,

faulty regulator or ECU /

Connections

192

DIAGNOSTIC TROUBLE CODES (DTC)

4 P1342

ECU

Supply

Voltage

Low

This Trouble Code sets if the ECU

Supply Voltage is below 10.00V

Can be based by faulty wiring,

faulty regulator or ECU /

Connections

Critical Voltage 5201-

3 P1343

Critical

Supply

Voltage

High

This Trouble Code sets if the

Critical Supply Voltage is above

17.00V Can be based by faulty

wiring, faulty regulator or ECU /

Connections

4 P1344

Critical

Supply

Voltage

Low

This Trouble Code sets if the

Critical Supply Voltage is below

10.00V Can be cbased by faulty

wiring, faulty regulator or ECU /

Connections

Chassis

Voltage

5201-

3 P1345

Chassis

Supply

Voltage

High

This Trouble Code sets if the

Chassis Supply Voltage is above

18.00V Can be based by faulty

wiring, faulty regulator or ECU /

Connections

4 P1346

Chassis

Supply

Voltage

Low

This Trouble Code sets if the

Chasssis Supply Voltage is below

14.00V Can be based by faulty

wiring, faulty regulator or ECU /

Connections

22V Injector

Voltage

5201-

3 P1347

Peak

Injector

Voltage

High

This Trouble Code sets if the Peak

Injector Supply Voltage is above

24.00V Can be based by faulty

wiring, faulty regulator or ECU /

Connections

4 P1348

Peak

Injector

Voltage

Low

This Trouble Code sets if the Peak

Injector Supply Voltage is below

20.00V Can be based by faulty

wiring, faulty regulator or ECU /

Connections

Throttle Safety

Switch

5201-

3 P1555

Throttle

Release

Switch

Signal

Circuit

Short to

Voltage

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

Throttle

Release

Switch

Signal

Circuit

Short to

Ground

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

Throttle

Stuck

Error

This Trouble Code Sets if the

Throttle Release Switch Signal

Indicates a Throttle Stuck Open.

193

DIAGNOSTIC TROUBLE CODES (DTC)

Can be caused by a Stuck Throttle

or Misadjusted/Stuck Throttle

Linkage.

Accessory

Relay

5202-

3 P1647

Accesso-

ry Relay

Driver

Circuit

Short to B

This Trouble Code Sets if the

Accessory Relay Driver Circuit is

Shorted to Voltage. Can be caused

by Damaged Wiring/Connections, a

Faulty Accessory Relay or ECU

5 P1646

Accesso-

ry Relay

Driver

Circuit

Open

This Trouble Code Sets if the

Accessory Relay Driver Circuit is

Open. Can be caused by Damaged

Wiring/Connections, a Accessory

Ignition Relay or ECU

Battery Charge

Relay

5202-

3 P163D

Charge

Relay

Driver

Circuit

Short to B

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

5 P163C

Charge

Relay

Driver

Circuit

Open

This Trouble Code Sets if the

Charge Relay Driver Circuit is

Open. Can be caused by Damaged

Wiring/Connections, a Charge

Relay or ECU

Oil Pump/

Injector Offset

5202-

41 13 P1278

Oil Pump

or Fuel

Injector

Offset not

Program-

med

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

PPM

5202-

42 13 P1279

Ground

Speed

Pulses

Per Mile

not

Program-

med

This Trouble Code Sets if the

Vehicle Speed Sensor Setting is

Not Properly Programmed in the

ECU Reset the ECU Offset Values

to Resolve this Fault Condition.

EV Position 5201-

16 P2627

Actuator

Position

High in

Open

Position For all E-VES Diagnostic Trouble

Codes (DTCs), see: page 197.

18 P2628

Actuator

Position

Low in

Open

Position

194

DIAGNOSTIC TROUBLE CODES (DTC)

5201-

16 P2629

Actuator

Position

High in

Mid

Position

18 P2630

Actuator

Position

Low in

Mid

Position

5201-

16 P2631

Actuator

Position

High in

Closed

Position

18 P2632

Actuator

Position

Low in

Closed

Position

EV Position

Faults

5203-

25 31 P140A

Exhaust

Valve

Position

Out of

Range

(Open)

5203-

26 31 P140B

Exhaust

Valve

Position

Out of

Range

(Mid)

5203-

27 31 P140C

Exhaust

Valve

Position

Out of

Range

(Closed)

EV Learn 5203-

3 P140E

Exhaust

Valve

Learn /

Gauge

Relay

Short to

Voltage

5 P140D

Exhaust

Valve

Learn /

195

DIAGNOSTIC TROUBLE CODES (DTC)

Gauge

Relay

Open

Circuit

Actuator

Diagnostic

5203-

34 31 P1409

Actuator

Overheat

Condition

5203-

3 P1406

Actuator

Position

Driver

Voltage

High

5 P1407

Actuator

Position

Driver

Voltage

Low

10 P1408

Actuator

Position

Abnormal

Rate of

Change

5203-

37 31 P1410

Actuator

Learning

Default

Position

5203-

65 16 P1605

Regulator

Tempera-

ture

Alarm

Actuator

Feedback

Faults

5203-

2 P1313

Exhaust

Valve

Actuator

Feedback

Set

Signal

Missing

7 P1316

Exhaust

Valve

Actuator

Feedback

Position

Fault

8 P1319

Exhaust

Valve

Actuator

196

DIAGNOSTIC TROUBLE CODES (DTC)

Feedback

Signal

Missing

12 P1317

Exhaust

Valve

Actuator

Feedback

Actuator

Failure

13 P1318

Exhaust

Valve

Actuator

Feedback

Calibra-

tion Fault

Brake Engaged

5205-

55 31 C2418

Riding

With

Brakes

Moder -

ately

Severe

This Trouble Code Sets if the Sled

has been driven with the brakes

applied continuously for 10

seconds, 4500 RPM

5205-

56 31 C2419

Ridiing

With

Brakes

On Most

Severe

This Trouble Code Sets if the Sled

has been driven with the brakes

applied continuously for 20 seconds

, 4500 RPM

E-VES DIAGNOSTIC TROUBLE CODES (DTCS)

SPN = SUSPECT PARAMETER NUMBER / FMI = FAILURE MODE INDICATOR

P-CODE SPN FMI DESCRIP-

TION

LIKELY CAUSE

(S)

ECU

RESPONSE

PRIMARY

COURSE OF

ACTION

P1400

5203-

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

197

DIAGNOSTIC TROUBLE CODES (DTC)

E-VES DIAGNOSTIC TROUBLE CODES (DTCS)

SPN = SUSPECT PARAMETER NUMBER / FMI = FAILURE MODE INDICATOR

P-CODE SPN FMI DESCRIP-

TION

LIKELY CAUSE

(S)

ECU

RESPONSE

PRIMARY

COURSE OF

ACTION

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

Fuel

according to

actual valve

position

See actions for

P140A / B / C

198

DIAGNOSTIC TROUBLE CODES (DTC)

E-VES DIAGNOSTIC TROUBLE CODES (DTCS)

SPN = SUSPECT PARAMETER NUMBER / FMI = FAILURE MODE INDICATOR

P-CODE SPN FMI DESCRIP-

TION

LIKELY CAUSE

(S)

ECU

RESPONSE

PRIMARY

COURSE OF

ACTION

Will also trigger

one of the

following:

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

5203-

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

Position

forced to last

known state,

fuel according

to last known

state

Inspect EV cable

for damage or

loose attachment at

valve assembly

199

DIAGNOSTIC TROUBLE CODES (DTC)

E-VES DIAGNOSTIC TROUBLE CODES (DTCS)

SPN = SUSPECT PARAMETER NUMBER / FMI = FAILURE MODE INDICATOR

P-CODE SPN FMI DESCRIP-

TION

LIKELY CAUSE

(S)

ECU

RESPONSE

PRIMARY

COURSE OF

ACTION

Command wire

(Dark Blue /

White) short to

+12V

Command wire

(Dark Blue /

White) short to

GND

P1409 5203-

34 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 5203-

37 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 5203-

25 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 5203-

26 31

Valve MID

position not

achieved

Valve MID

position voltage

out of range

P140C 5203-

27 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:

200

DIAGNOSTIC TROUBLE CODES (DTC)

E-VES DIAGNOSTIC TROUBLE CODES (DTCS)

SPN = SUSPECT PARAMETER NUMBER / FMI = FAILURE MODE INDICATOR

P-CODE SPN FMI DESCRIP-

TION

LIKELY CAUSE

(S)

ECU

RESPONSE

PRIMARY

COURSE OF

ACTION

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

5203-

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

201

DIAGNOSTIC TROUBLE CODES (DTC)

202

TROUBLESHOOTING

ENGINE TROUBLESHOOTING

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.

Your dealer can perform

this service.

Machine fails to

move

Clutch jammed Check for twisted belt or

broken spring. Your dealer

can perform this service.

Track jammed • Foreign object may be

caught or the rail slide

melted to the track clips

due to lack of lubrication.

• Track may be iced up or

frozen to the ground.

Chaincase sprocket or

chain jammed or broken

Chain is loose or broken or

chain tightener is loose.

Your dealer can perform

this service.

203

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE SOLUTION

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

204

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE SOLUTION

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 • Make sure the fuel valve

is on.

• Make sure tank contains

fuel.

• Ice may be in the fuel

line, filter or pump. Add

isopropyl alcohol to the

fuel system.

• Your dealer can perform

this service.

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).

205

TROUBLESHOOTING

PROBLEM PROBABLE CAUSE SOLUTION

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.

SUSPENSION TROUBLESHOOTING

PROBLEM SOLUTION

Rear suspension

bottoms too easily • Refer to the Suspension Quick Set-Up Guide for

details.

• Revalve rear track shock (see your dealer).

Rides too stiff in rear • Refer to .

• Check for binding suspension shafts and grease

all pivot points.

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 • See your dealer for ski alignment inspection.

• Make sure spindles and all steering components

turn freely.

• Check for excessive play in steering assembly

(your dealer can assist).

• Ensure skags are straight on skis.

206

TROUBLESHOOTING

PROBLEM SOLUTION

Front end pushes • Refer to the Suspension Quick Set-Up Guide for

details.

• Check for worn skags.

• Check for binding front suspension shafts and

steering components, grease all pivot points

(elevate front of snowmobile).

• Increase IFS preload (if equipped).

Steering is heavy • Refer to the Suspension Quick Set-Up Guide for

details.

• Make sure spindles and all steering components

turn freely.

• See your dealer for ski alignment inspection.

• Check skags and skis for damage.

DRIVE BELT TROUBLESHOOTING

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.

207

TROUBLESHOOTING

BELT WEAR/BURN DIAGNOSIS

CAUSES SOLUTIONS

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.

TROUBLESHOOTING (DET)

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

DIAGNOSTIC DISPLAY CODE DEFINITIONS

Open Load: There is a break in the wires that lead to the item listed in the chart

(injector, fuel pump, etc.), or the item has failed.

Short-to-Ground: The wire is shorted to ground between the electronic control

unit and the item listed in the chart.

Shorted Load: The wires leading to the item listed in the chart are shorted

together, or the item has shorted internally.

Short-to-Battery: The wire leading from the item listed in the chart to the

electronic control unit is shorted to a wire at battery voltage.

208

TROUBLESHOOTING

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

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

210

TROUBLESHOOTING

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

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

211

TROUBLESHOOTING

WARRANTY

SERVICE AND WARRANTY INFORMATION

OBTAINING SERVICE AND WARRANTY

ASSISTANCE

Read and understand the service data and the POLARIS warranty information

contained in this manual. Contact your POLARIS dealer for replacement parts,

service or warranty. Your dealer receives frequent updates on changes,

modifications and tips on snowmobile maintenance, which may supersede

information contained in this manual. Your dealer is also familiar with POLARIS

policies and procedures and will be happy to assist you.

When contacting us about parts, service, or warranty, always provide the

following information:

1. Serial number

2. Model number

3. Dealer name

4. Date of purchase

5. Details of trouble experienced

6. Length of time and conditions of operation

7. Previous correspondence

Use the page provided near the front of your owner’s manual to record the

identification numbers of your snowmobile and its engine.

POLARIS CUSTOMER SERVICE

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

213

WARRANTY

LIMITED WARRANTY

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.

REGISTRATION

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.

214

WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS

LIMITATIONS OF WARRANTIES AND REMEDIES

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

215

WARRANTY

LUBRICANTS AND FLUIDS

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.

HOW TO OBTAIN WARRANTY SERVICE

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.

216

WARRANTY

IN THE COUNTRY WHERE YOUR PRODUCT WAS

PURCHASED:

Warranty or service bulletin repairs must be done by an authorized POLARIS

dealer. If you move or are traveling within the country where your product was

purchased, warranty and service bulletin repairs may be requested from any

authorized POLARIS dealer that sells the same line as your product.

OUTSIDE THE COUNTRY WHERE YOUR PRODUCT

WAS PURCHASED:

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:

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 FROM A PRIVATE PARTY:

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.

217

WARRANTY

EXPORTED PRODUCTS

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.

NOTICE

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

218

WARRANTY

U.S.A. EPA EMISSIONS LIMITED WARRANTY

This Emissions Limited Warranty is in addition to the POLARIS standard Limited

Warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is

first purchased, this emissions-certified vehicle is designed, built and equipped

so it conforms with applicable U.S. 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

219

WARRANTY

222

Diagnostic Display Mode. . . . . . . . . . . . . 58

Disabled Operators . . . . . . . . . . . . . . . . . . . . 15

Display, Standard/Metric . . . . . . . . . . . . . 45

Drive Belt

Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Drive Belt Break-In. . . . . . . . . . . . . . . . . . . . . 92

Drive Belt Deflection. . . . . . . . . . . . . . . . . 122

Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 122

Drive Belt Storage . . . . . . . . . . . . . . . . . . . 143

Drive Chain Tension . . . . . . . . . . . . . . . . . . 117

Driver Awareness . . . . . . . . . . . . . . . . . . . . . . 15

Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . . 23

Driving in Hilly Terrain . . . . . . . . . . . . . . . . . 23

Driving on Slippery Surfaces . . . . . . . . 22

Driving Responsibly . . . . . . . . . . . . . . . . . . . 25

E-VES

Diagnostic Trouble Codes . . . . . . 197

Emission Control Information . . . . . 101

Emission Control Label . . . . . . . . . . . . . 101

Emission Control Maintenance

Requirements . . . . . . . . . . . . . . . . . . . . . . . 101

Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . 90

Engine Overheating . . . . . . . . . . . . . . . . . . . 61

Engine Restarting. . . . . . . . . . . . . . . . . . . . . . 90

Engine Serial Number . . . . . . . . . . . . . . . . 10

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . 89

Engine Stop Switch . . . . . . . . . . . . . . . 88, 95

Engine Stop Switch Alignment. . . . . . 80

Engine-Cooling Actions. . . . . . . . . . . . . . . 62

Environment Preservation . . . . . . . . . . . . . 8

Exhaust System . . . . . . . . . . . . . . . . . . . . . . . 116

Exported Products . . . . . . . . . . . . . . . . . . . 218

Extended Idle Engine Shutoff . . . . . . . 38

Fasteners, Hood and Side Panel. . . 88

Fluid Change

Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Fluid Change, Chaincase . . . . . . . . . . 107

Fluid Change:Coolant. . . . . . . . . . . . . . . . 114

Fluid Level

Brake Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Chaincase . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Front (IFS) Shock Adjustments . . . . . 73

Front Suspension Inspection. . . . . . 128

Front Track Shock Factory

Spring Settings . . . . . . . . . . . . . . . . . . . 66, 68

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Fuel Recommendation. . . . . . . . . . . . . . . . 93

Fuel System Deicers . . . . . . . . . . . . . . . . . . 94

Fuel Type Selection . . . . . . . . . . . . . . . . . . . 60

Fuse Replacement. . . . . . . . . . . . . . . . . . . 121

Hand Control Alignment

Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Hand Control Alignment, Left . . . . . . . 78

Hand Control Alignment, Stop

Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Handlebar Angle . . . . . . . . . . . . . . . . . . . . . . . 76

Handlebar Component

Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Handlebar Components . . . . . . . . . . . . . . 79

Headlight Adjustment . . . . . . . . . . . . . . . . . 35

Helmet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Hood Access . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Hood Fasteners . . . . . . . . . . . . . . . . . . . . . . . . 88

Hood Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

IFS Shock Factory Clicker

Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

IFS Shock Spring Settings . . . . . . . . . . . 73

Ignition Lock System . . . . . . . . . . . . . . . . . . 46

Ignition Switch . . . . . . . . . . . . . . . . . . . . . 33, 88

Inadequate Snow Conditions . . . . . . . 22

Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . 40

226

INDEX

Information Display Area . . . . . . . . . . . . . 42

Inspection, Pre-Ride. . . . . . . . . . . . . . . . . . . 83

Instrument Cluster . . . . . . . . . . . . . . . . . . . . . 39

Instrument Cluster, PIDD. . . . . . . . . . . . . 59

Intake Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Intake Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Interactive Digital Display

(PIDD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Key Identification . . . . . . . . . . . . . . . . . . . . . . . 10

Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Limited Warranty . . . . . . . . . . . . . . . . . . . . . 214

Locking System With Personal

Security Code . . . . . . . . . . . . . . . . . . . . . . . . . 53

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Lubrication, Rear Suspension . . . . 106

Maintenance

Cooling System Bleeding . . . . . . . . 115

Periodic Chart. . . . . . . . . . . . . . . . . . . . . . 103

Maintenance Log. . . . . . . . . . . . . . . . . . . . . 223

Maintenance Recommendations . . . 11

Maneuverability. . . . . . . . . . . . . . . . . . . . . . . . . 24

Metric/Standard Display . . . . . . . . . . . . . . 45

Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Mountainous Terrain Riding . . . . . . . . . 16

Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Non-ionizing Radiation. . . . . . . . . . . . . . 101

Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Odometer/Engine Hour Display

Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Oil Change, Chaincase . . . . . . . 107-108

Oil Injection System . . . . . . . . . . . . . . . . . . . 91

Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Oil Level, Chaincase . . . . . . . . . . . . . . . . 106

Oil Level, Injection . . . . . . . . . . . . . . . . . . . . . 94

Oil Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Oil Pump Failure Protection . . . . . 37-38

Oil Recommendations . . . . . . . . . . . . . . . . 90

Operating Area . . . . . . . . . . . . . . . . . . . . . . . . . 88

Operating in Deep Snow . . . . . . . . . . . . . 22

Operation Warning. . . . . . . . . . . . . . . . . . . . . 29

Operator Safety. . . . . . . . . . . . . . . . . . . . . 11-12

Overheating, Engine . . . . . . . . . . . . . . . . . . 61

Parking Brake Lever Lock. . . . . . . . . . . . 86

Playback Function . . . . . . . . . . . . . . . . . . . . . 43

Pre-Ride Checklist. . . . . . . . . . . . . . . . . . . . . 83

Pre-Ride Suspension Inspection. . . 84

Rail Scratchers . . . . . . . . . . . . . . . . . . . . . . . . . 37

Rail Slide Wear Inspection. . . . . . . . . 131

Rear Rear Scissor Stop (RRSS) . . . 71

Rear Track Shock Adjustments. . . . . 65

Rear Track Shock Factory

Clicker Settings . . . . . . . . . . . . . . . . . . . . . . . 69

Recoil Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Recoil Rope Inspection . . . . . . . . . . . . . . . 88

Recommended Maintenance . . . . . 102

Registration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Reverse Operation. . . . . . . . . . . . . . . . . . . . . 97

Reverse Warning. . . . . . . . . . . . . . . . . . . . . . . 27

Rider Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Rider Information Center . . . . . . . . . . . . . 41

Riding Apparel . . . . . . . . . . . . . . . . . . . . . . 13-14

Riding Position. . . . . . . . . . . . . . . . . . . . . . . . . . 12

Riser Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

227

INDEX

Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Security System . . . . . . . . . . . . . . . . . . . . . . . . 46

Shock Compression Damping . . . . . . 64

Shock Locations. . . . . . . . . . . . . . . . . . . . . . . . 64

Side Panel Access. . . . . . . . . . . . . . . . . . . . 110

Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Skags, Carbide . . . . . . . . . . . . . . . . . . . . . . . . . 82

Ski Alignment . . . . . . . . . . . . . . . . . . . . . . . . . 129

Ski Skags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Slide Rail and Track Cooling . . . . . . . . 93

Snow Conditions . . . . . . . . . . . . . . . . . . . . . . . 22

Spark Plug Condition. . . . . . . . . . . . . . . . . 113

Spark Plug Inspection. . . . . . . . . . . . . . . . 112

Spark Plug Recommendations . . . . 111

Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Specifications

600 INDY SP . . . . . . . . . . . . . . . . . . . . . . . 155

600 INDY SP/XC/ADV . . . . . . . . . . . 157

600 RMK 144 . . . . . . . . . . . . . . . . . . . . . . 151

600 SB Assault . . . . . . . . . . . . . . . . . . . . 149

600 Voyageur . . . . . . . . . . . . . . . . . . . . . . 153

800 INDY XC/ADV. . . . . . . . . . . . . . . . 165

800 INDY XC/XCR. . . . . . . . . . . . . . . . 163

800 SB Assault . . . . . . . . . . . . . . . . . . . . 159

800 SKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

850 INDY XC/ADV 137 . . . . . . . . . . 174

850 INDY XC/XCR. . . . . . . . . . . . . . . . 171

850 SB Assault . . . . . . . . . . . . . . . . . . . . 167

850 SKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Spindle bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Standard/Metric Display . . . . . . . . . . . . . . 45

Starting the Engine . . . . . . . . . . . . . . . . . . . . 89

Steering System. . . . . . . . . . . . . . . . 127-128

Steering System Inspection . . . . . . . . . 87

Steering/Suspension Maintenance

Adjustable Riser. . . . . . . . . . . . . . . . . . . . . 77

Stopping, Emergency . . . . . . . . . . . . . . . . . 98

Storage, Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Survival Preparation. . . . . . . . . . . . . . . . . . . 14

Suspension Inspection, Pre-

Ride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Suspension Lubrication, Rear . . . . 106

Suspension mounting bolts . . . . . . . . . . 84

Suspension Quick Set-Up

Guide . . . . . . . . . . . . . . . . .

63-64, 66, 68, 73

Switches

Engine Stop Switch. . . . . . . . . . . . . . . . . 95

Ignition Switch . . . . . . . . . . . . . . . . . . 33, 88

Mode/Select Buttons . . . . . . . . . . 39, 59

Mode/Set Switch . . . . . . . . . . . . . . . 39, 59

Tether Switch. . . . . . . . . . . . . . . . . . . . . . . . . 88

Throttle Safety Switch. . . . . . . . . 85, 96

Temperature Charts . . . . . . . . . . . . . . . . . . . 26

Tether Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Throttle Block Alignment . . . . . . . . . . . . . 80

Throttle Lever . . . . . . . . . . . . . . . . . . . . . . 85, 95

Throttle Lever Inspection. . . . . . . . . . . . . 85

Throttle Safety Switch. . . . . . . . . . . . . . . . . 96

Throttle Safety Switch

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Track

Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Track Inspection. . . . . . . . . . . . . . . . . . . . . . . . 87

Track Maintenance . . . . . . . . . . . . . . . . . . 124

Track Studding. . . . . . . . . . . . . . . . . . . . . . . . . . 81

Track Tension Data Chart . . . . . . . . . . 125

Track Warm-Up . . . . . . . . . . . . . . . . . . . . . . . . . 92

Track Warning . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Transporting the Snowmobile . . . . . 141

Treating the Fuel System . . . . . . . . . . 142

Troubleshooting, Drive Belt. . . . . . . . 207

Troubleshooting, Engine . . . . . . . . . . . 203

Troubleshooting, Suspension . . . . . 206

Unlocking System With

Personal Security Code. . . . . . . . . . . . . 55

228

INDEX

Product specificaties

Merk:	POLARIS
Categorie:	Niet gecategoriseerd
Model:	800 Indy Adventure 137 (2020)

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