Polaris 600 RUSH Bedienungsanleitung

P antone 425C TM[...]

WARNING Read, understand, and follow all of the in structions and safe ty precautions in this manual and on all produ ct labels. F ailure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product co ntains chemicals known to th e State of California to cau se cancer , birth defects or oth[...]

The text is printed on 100% recycled with 40% post-consumer waste (PCW).[...]

For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922276 Rev 02 Printed in USA P antone 425C[...]

1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris enthusiasts. Be sure to visit us online at www .polarisindustries.com for the la test news, new product introduc- tions, upcoming events, car eer opportunities and more. Here at Polaris we proudly produce an exciting line of utility and recre- at[...]

2 POLARIS and POLARIS TH E W A Y OU T are regist ered trademarks of Pola ris Indus- tries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discre[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This section contains helpful info rmation for own ers and drivers and illustrates the location of important identification numbers that should be recorded in the owner's manual. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8[...]

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5 INTRODUCTION Import ant Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when th e snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations. Y our model may differ . Follow the maintenance program ou[...]

6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourage state and provin cial governments across the sn ow- belt to adopt rigorous safety traini ng programs that encourage protection of our environment, includ ing wildlife and vegetation. Snowmobile clubs and o ther orga[...]

7 INTRODUCTION V ehicle Identification Numbers Record your snowmobile 's identification numb ers and key number in the spaces provided. Remove the spare key and store it in a safe place. Y our key can be duplicated only by mating a Polari s key blank wi th one of your existing keys, so if both keys are lost, the ignition switch must be replace[...]

8 SAFETY Operator Safety The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal injury ha zard. WA R N I N G A W ARNING indicate[...]

9 SAFETY Operator Safety Follow the recommended mainte nance program beginn ing on page 73 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your d ealer at specific mileage intervals. Driving a snowmobile requires your full atten tion. DO NOT drink alcohol or use drugs or medications before or whil[...]

10 SAFETY Operator Safety St ay Clear of T rack Y our snowmobile is propelled by a revo lving track that must be part ially exposed for proper operation. Do not stand on the plastic flap. W ARNING! 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[...]

11 SAFETY Operator Safety Riding App arel Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Ca nada bear a U.S. Dep artment of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceani[...]

12 SAFETY Operator Safety Disabled Operators Safe operation of this rider -active vehicle requires good judgement and physical skills. Operators with cognitiv e or physical disabilities have an increased risk of loss of control, wh ich could result in serious injury or death. Survival Prep aration For your safety , always ri de in a group of o ther[...]

13 SAFETY Operator Safety Rider Cap acity This snowmobile is designed for a single rider only . Never carry a pas- senger on this snowmobile. Excessive Speed W ARNING! High speed driving, especially at night , could result in serious injury or death. Always reduce speed when drivin g at night or in inclement wea ther . Always observe all state an d[...]

14 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snow mobiling 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 d[...]

15 SAFETY Operator Safety A valanches Snowmobilers should always be properl y trained and equipped before traveling in mountainous terrain: • T ake an av alanche cl ass • T ravel with experienced people • T ravel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon. Y ou don't have to be sn[...]

16 SAFETY Operator Safety Ice and Snow Build-up W ARNING! Ice and snow build-up may interf ere with the steering of your snowmobile, resulting in serious injury or death. Ke ep t he underhood area free of snow and ice. Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full left and right [...]

17 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weig ht 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. W ARNING! When driving on long downh[...]

18 SAFETY Operator Safety Drive Belt Do not operate the engine wi th the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer . NOTICE: Operation of the engine with the belt re moved may result in injury or damage to the engine. Int ake Silencer Do not operate the engine with the intake silencer [...]

19 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the most docile condi- tions may become dangerous if oper ators drive improp erly . If you're new to snowmobiling, acquaint yourse lf with the snowmobile and with what it will and won't do under va rious conditions. Even seasoned driv- ers should[...]

20 SAFETY Operator Safety Windchill/T emperature Chart s The following informatio n is provided to help you d etermine when tem- peratures become da ngerous for riding. WINDCHILL CHART ( _ F) WINDCHILL CHART ( _ C) Wind S peed 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 T emperatur[...]

21 SAFETY Safety Labels and Locations W arning labels have been placed on the snowmobile for your protection . Read and follow the instru ctions of the labels and other warnings on the snowmobile carefully . If any of the labe ls depicted in this manual differ from the labels on your snowmobi le, always read and follow the instruc- tions of the lab[...]

22 SAFETY Safety Labels and Locations T rack W arning The track warning label is at the rear of the snowmobile: W ARNING St ay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. “No Passenger” W arning Snowmobiles designed for a single rider only have the NO P A SS[...]

23 SAFETY Safety Labels and Locations Operation W arning The operation warning la bel is also located on the console. • T o avoid serious injury or death , read and understand all warnings and the Owner's Manu al before opera tion. If manual is missing, contact a Polaris dealer for a replacement. • This vehicle is capable of high speeds. B[...]

24 FEA TURES 8 13 5 6 7 12 11 2 1 3 4 10 9 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. W indshield (accessory) 7. Handlebar 8. Operator Seat 9. T aillight 10. Rear Bumper 11 . S n o w F l a p 12. Suspension 13. T rack 14. Side Panel 15. Side Panel Fast eners 15 14[...]

25 FEA TURES 1. Fuel Filler Cap 2. Brake Lever 3. MFD Gauge 4. Ignition Switch 5. Engine S top Switc h 6. Throttle Control 7. Recoil S tarter Handle 8. Parking Brake Lock 9. Handlebar Grip W armer Switch 10. Thumbwarmer Switch 1 1. Electro nic Reverse But ton 12. Mode Switc h 13. Headlight Dimmer Switch 1 4 5 6 7 3 2 12 11 13 89 1 0[...]

26 FEA TURES S torage Bag/T ool Kit A storage bag i s located under the s eat. The left portion of the bag is designed to store the tool kit. The to ol kit includes tools and a foam tool holder . The right side of the bag can be used to stow other item s. Adjust able Headlight s Move the headlight adjuster to the left to adjust the headlight beam u[...]

27 FEA TURES Detonation Elimination T echnology (DET) The DET system prevents damage to the engine from deton ation by going into an engine protection mo de whenever the DET system is active. Depending on the level of detonation encountered, the check engine light could be so lid, it could flicker or it could flash steadily . When excessive detonat[...]

28 FEA TURES Instrument Cluster The instrument clu ster contains indicator lights an d the rider infor- mation center . The information cen- ter can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the MODE/ SET switch on th e left handlebar . NOTICE: Certain products will damage the lens and other plastic sur- fa[...]

29 FEA TURES Instrument Cluster Indicators Check Engine Indicator This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning app ears. Serious engine damage cou ld result. See your dealer . See page 36 for diagnostic code definitions. Over-T emperature Indicator This indicator illuminates to alert the opera[...]

30 FEA TURES Instrument Cluster Rider Information Center The rider information center is locat ed in the instrument cluster . The center displays vehicle speed, engine speed, odometer , resettable trip meters (2), total engine hours o f op eration, fuel level, engine tempera- ture and diagnostic display mode. Setting changes can be made with the en[...]

31 FEA TURES Instrument Cluster Rider Information Center 1. Information Display Area - This area displays either engine spe ed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. T o change the dis- play , see page 32. 2. Speed Display - The speed display area displays either vehicle spe[...]

32 FEA TURES Instrument Cluster Rider Information Center Spe ed Display Area The speed display area displays eith er vehicle speed or engine speed. V ehicle speed is dis played in either miles per hour (MPH) or kilometers per hour (km/h). En gine speed is disp layed in revolutions per minute (RPM). 1. T o change which item displays, fi rst make sur[...]

33 FEA TURES Instrument Cluster Rider Information Center Odometer/Engine Hour Display Area This area displays the odometer , T rip A meter , T rip B meter and engine hours meter . The odometer displays the total dist ance traveled by the vehicle since manufacture. Each trip meter rec ord s the distance traveled by the vehi- cle on a trip if the met[...]

34 FEA TURES Instrument Cluster Rider Information Center St a ndard/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 rema in until changed by the operator . Change Method 1 1. Pr ess and r elease the MODE button or M[...]

35 FEA TURES Instrument Cluster Rider Information Center Diagnostic Display Mode The diagnostic display mode is fo r informational pu rposes only . Please see your Polaris dealer for all major repairs. The diagnostic mode is accessible on ly when the check engine warning indicator is illuminated and a di agnostic code is active. Do not stop the eng[...]

36 FEA TURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (inj ector , 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. Sh[...]

37 FEA TURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Diagnostic Codes Component Con dition SPN FMI Ignition Coil Primary Driver 1 (M AG) Driver Circuit Open/Grounded 1268 5 Fuel Pump Driver Circuit Driver Circuit Open/Grounded 1347 5 Chassis Relay Driver Circuit Open/Grounded 520208 5 Driver Circuit Short to [...]

38 THE PERFECT FIT Suspension Quick Set-Up Guide The suspension on your RUSH is in credibly easy to adjust to your weight and riding style. Just remember three simple steps: 1. Set up rear sho ck spring preload for rider wei ght. 2. Adjust the r ear spring to tune vehicle balance (ski pressure and weight transfer). 3. Adjust shock clickers to tune [...]

39 THE PERFECT FIT Suspension Quick Set-Up Guide Step 2: Adjust the rear spring to tune vehicle balance. After the initial test ride, make adjust ments to the rear shock spring to improve vehicle balance. Increasing preload will increase ski pressure and result in less weight transfer for flatter cornering and more precise steering response. Decrea[...]

40 THE PERFECT FIT Suspension Quick Set-Up Guide Accessory rear shock springs are available for riders of different weights. A corresponding gaug e is available for each spring type. The gauge provided with your snowmo bile is calibrated for the stock 190 spring, which shou ld be used by most riders. Do not change springs unless your weight is at t[...]

41 THE PERFECT FIT Suspension Quick Set-Up Guide Polaris recommends that riders use this Quick Set-Up Guide to make any adjustments for rider weight an d trail conditions. If additional tun- ing is needed after yo u have exhaus ted all possi ble adjustments to the rear shock spring and clicker , refer to the information on the following pages of th[...]

42 THE PERFECT FIT Front Suspension Adjustment s Independent Front Suspension (IFS) Factory settings, combined with user adjustments to the rear shock spring, should be all that’ s necessa ry to provide the best riding experi- ence for most riders. If all rear sh ock sp ring adjustments have been exhausted and rider weight is at the very hig h or[...]

43 THE PERFECT FIT Front Suspension Adjustment s IFS Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pres- sure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. The initial IFS preload setting is[...]

44 THE PERFECT FIT Front Suspension Adjustment s IFS Shock Compression Damping Make adjustments to the shock clicke rs to control bottoming. Make the adjustments in 1-to-2-click increments, then test ride. Repeat the adjust- ment until the desired result is achieved. TIP: Initiall y , heavier riders may want to se t the shock clickers 2-4 clicks hi[...]

45 THE PERFECT FIT Rear Suspension Adjustment s Rider weight, riding style, trail co nditions, and vehicle speed all af fect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However , all sus- pension design s and adjustment s involve a compromis e, or [...]

46 THE PERFECT FIT Rear Suspension Adjustment s Front T rack Shock Compression Damping Make adjustments to the shock clicker to control bottoming. Make the adjustments in 2-click incre- ments, then test ride. Repeat the adjustment until the desired result is achieved. TIP: Initiall y , heavier riders may want to set the shock clickers 2-4 clicks hi[...]

47 THE PERFECT FIT Rear Suspension Adjustment s Rear Shock Spring Preload Settings Make adjustments to the rear shock spring to tune vehicle balance. Increasing preload will increase ski pr essure and result in less weight transfer and flatter cornering and more precise steering response. Decreasing preload will decrease ski pr essure and result in[...]

48 THE PERFECT FIT Handlebar Adjustment s Handlebar Position 1. Loosen the four bolts on the bottom of the adjuster block. If necessary , pry the blocks apart with a screwdriver . 2. Adjust the handlebar forward or rearward to the desired position. 3. T ighten the bolts. Handlebar Angle 1. Loosen the four bolts on the top of the adjuster block. If [...]

49 THE PERFECT FIT Accessories Polaris offers a wide range of accesso ries for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • V oiding of warranty • Injury t[...]

50 THE PERFECT FIT T raction Product s Stu d s Use only Polaris traction prod ucts on your snowmo bile. T rack warran- ties are void if track damage or fa ilure results from improper or exces- sive stud installation or t he use of non-Polaris tractio n products. The longest stud length recom mended for your factory -installed track is 1 1/4 inches [...]

51 THE PERFECT FIT T raction Product s n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmob ile and t o prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain prop er vehicle steering and control. See page 1 05. If your[...]

52 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on th e checklist for proper operation or condition before each use of the snowmobile. Pr ocedures are outlined on the refer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspection items. Item See Page Drive Belt Condi tion 95 S teering System 57[...]

53 PRE-RIDE INSPECTIONS Pre-Ride Suspensio n Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Befo re beginning any snowmobile trip, a visual inspection will uncover po tential problems. Check the follow- ing items on a weekly basis or before any long trip. Item See Page Check s[...]

54 PRE-RIDE INSPECTIONS Before St arting the Engine Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of prop er operation. W ARNING! Operating the vehicle with worn , damaged, or malfunctioning components could result in ser[...]

55 PRE-RIDE INSPECTIONS Before St arting the Engine n Brakes Always check the following items fo r proper operation before starting the engine. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip than 1/2 I (1.3 cm). A smaller distance indicates low brake fluid leve l or air in the hydraulic system. Refer to the b[...]

56 PRE-RIDE INSPECTIONS Before St arting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary; for ex ample, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reservoir/ Cover 4. Fluid Level Indicato r[...]

57 PRE-RIDE INSPECTIONS Before St arting the Engine n Steering System W ARNING! Ice and snow build-up may interf ere with the steering of your snowmobile, resulting in serious inju ry or death. Ke ep t he underhood area free of snow and ice. Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering wi[...]

58 PRE-RIDE INSPECTIONS S t art the Engine and Check Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation. Never en gage the starter w hen the engine is running. Never start the engine with out checking all ve hicle components to be sure of proper operatio n. See Before Starting the Engine beginning on[...]

59 OPERA TION S t arting the Engine NOTICE: Engaging the starter when the engine is run ning WILL result in serious engine damage, especially if the tr ansmission is in reverse. Never engage the starter when the engine is runni ng. 1. T urn the key to the ON position. 2. Pull the engine stop switc h up to the RUN position. 3. If equipped with elect[...]

60 OPERA TION Engine Break-In No single action on your part is as important to long, trouble-free snow- mobile life as proper break-in of a new or rebuilt engine. Premix the first tank of fuel with one pint of Polaris injection o il for each five gal- lons of fuel. This, in addition to th e lubrication supplie d by the injection system, will assure[...]

61 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil bottle when refuel ing. See page 65. NOTICE: Serious engine damage can occur without the proper lubrication . Check the oil bottle level often during the first tank of fuel. If the oil level doesn't go down , contact your dealer immediately . Oil Recommendations T[...]

62 OPERA TION T rack W arm-Up W ARNING! A loose track or flying debris could cause serious injury or death. S tand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand be hind it while warmin g up the track. D o not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear[...]

63 OPERA TION Fuel Gasoline is highl y flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling gasoli ne. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or allow open f[...]

64 OPERA TION Fuel Resistor This snowmobile is equipped with a feature that allows the engine control- ler to select the proper operating soft- ware based on the type of fuel being used. The proper fuel resistor must be installed to match the type of fuel you are using. The snowmobile comes from the fac- tory with the resistor installed that should[...]

65 OPERA TION n Oil Low Oil Level Always maintain the oil level between the “add” mark and the bottle neck. Do not fill the bottle neck. See page 61 for oil recommendations. 1. Immediately stop the engine if the low oil indicator light comes on. 2. Open the left side panel. 3. V iew the oil level in the oil bottle. 4. Add oil as needed before o[...]

66 OPERA TION n Engine S top Switch Push down on the engine stop switch ( + ) to ground out the ig nition and stop the engine quickly . Pull the switch up to the ON position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to stop the engi ne whenever all pressure is removed from the throttle lever and the thrott[...]

67 OPERA TION Throttle Lever W ARNING! An improperly functioning throttle lever may cause erratic snowmobile behavior and loss of control, wh ich could result i n serious injury or death. If the th rottle lever does not work properly , DO NOT start the engine. If the engine stops abruptly when the throttle lever is released: 1. T urn the ignition s[...]

68 OPERA TION Emergency S toppi ng The following chart lists methods for stopping the snowmobile in the event of an emergency . See page 66 for more information about the engine stop switch and throttle safety switch. SYSTEM WHA T IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine S top Switch Interrupts ignition circu[...]

69 OPERA TION Electronic Reverse (PERC t ) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Da mage will occur to the chaincase or trans- mission if shifting is attempted when the engine is operating above idle speed . • Shift to or from reverse only when the snowmobile is stopped an[...]

70 OPERA TION Electronic Reverse (PERC t ) Engaging Reverse 1. S top the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear . 3. Push the yellow reverse button on the left-hand control for one sec- ond, then release. The engine will automatically reduce RPM and start a reverse rotation. A flashing reverse lig[...]

71 OPERA TION Daily St orage At the end of each ride, park the snowmobi le on a level surface and sup- port it at the rear with an appropri ate track stand. The track should be suspende d approximately 4 I (10 cm) of f the ground. Remove the key and cover the snowmobile. To w i n g For your safety , do not attempt to use a tow hitch until you'[...]

72 MAINTENANCE Emission Control Information Any qualified repair shop or qualifie d person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Y our snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa- [...]

73 MAINTENANCE Polaris Recommended Maintenance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform se rvice checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log begin ning on page 125. The recommended maintenance schedul e on your snowmobile[...]

74 MAINTENANCE Periodic Maintenance Interval T able The following chart is a guide based on average riding conditions. Y ou may need to increase frequency based on ri ding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer . I - Inspect (clean, adjust, tighten, lu[...]

75 MAINTENANCE Periodic Maintenance Interval T able Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season BRAKES Hose Routing -- II II Hose Condition -- II II Fluid Leaks -- II II Brake Pads 90 II II Brake Disc -- II II Parking Brakes 56 II II Brake System 55, 90 I Brake Fluid 91 R FUEL MANAGEME[...]

76 MAINTENANCE Periodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season CHASSIS Ski T oe Alignment -- II I Suspension Mounting Bolts -- II I I I S teering F[...]

77 MAINTENANCE Hood/Side Panel The hood and side panels of the snowmobile protect the operator from moving parts. Never op er- ate a snowmobile with the hood or side panels o pen or removed. Always ensure that the hood and side panels are securely in place before s tarting the engine. T o open a side panel, rotate the two 1/4-turn fasteners at the [...]

78 MAINTENANCE Lubrication n Chaincase Oil Check and change the chaincase oil at the intervals outlined in the main- tenance charts beginning on page 73. Maintain the oil level at the top of the fill plug hole. Polaris recommen ds the use of Polaris Synthetic Chaincase Lube. See page 1 10 for the part numbers of Polaris products. Oil Level 1. Posit[...]

79 MAINTENANCE Lubrication n Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan under the drain plug. Remove the drain plug. Allow the oil to drain completely . 3. Clean of f all metal shavings fro m the plug. Install a new sealing washer on the drain p lug. TIP: The seal ing surfaces on the drain plug and the[...]

80 MAINTENANCE Lubrication Rear Shock Body Threads Lubricate rear shock body threads seasonally . W e recommend the use of Polaris Shock Thread Lubricant, a silicone spray lubricant. This lubri- cant is specifically designed for cold temperatures and high loads. Other silicone lubricants will not perform as well. See page 1 10 for the part numbers [...]

81 MAINTENANCE Int ake 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 se rvice must be performed by an authorized Polaris dealer . Do not attempt to service the fuel pump. Fuel Filter/F[...]

82 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendatio ns A new engine can cause temporary spar k plug fouling du e to the preser- vative added during the assembly p rocess. A void prolonged idle speeds, which cause plug fouling and carbonization. Refer to your Owner's Manual Supplement for the specific spa rk plug to be used in your sn owm[...]

83 MAINTENANCE Spar k P l u g s Sp ark Plug Insp ection Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the eng ine has been warmed up and the vehicle has been driven at higher spe eds. Immediately check the spark plug for correct color . CAUTION! A hot exhaust system and engine can c[...]

84 MAINTENANCE Oil Lines Inspect oil line condition ev ery 1000 miles (1600 km). Oil Filter The oil filter is located at the side of the oil tank. Have your dealer chang e the oil filter and bleed the system annually or every 10 00 miles (1600 km). TIP: The dire ction of the arrows indicates the direction of flow through the fil- ter .[...]

85 MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water , which will provide adequate freeze protection under most conditions. If the vehicle will be stored or oper- ated at extremely low te mperatures , greater protectio n may be required. Please see your Pol[...]

86 MAINTENANCE Cooling System Engine Overheating The over -temperature indicator on the instrument cluster will illuminate when the engine is overheating. The indicator will flash when engine temperature reaches critical levels. Illuminated Indicator T ake action to cool the engine: • Drive in loose snow . • V iew the coolant level. Do not open[...]

87 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! S team and hot liquids will cause burn s 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, contac[...]

88 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approx imately 2000 miles (3200 km). Always allow the en gin e and exhaust system to cool completely before inspecting. CAUTION! Hot exhaust system parts can cause burns. Allow a dequate time for the exhaust system to cool. Never perfo rm this procedure with the engine run[...]

89 MAINTENANCE Drive Chain T ension Check drive ch ain tension weekly and before each long trip. 1. Remove th e 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 tighte[...]

90 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 55. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing pl ate (approximately 1/16 I ). A kit is available for replacing brake pads. S ee your dealer . W ARNING! Brake failure during ope[...]

91 MAINTENANCE Brakes Brake Fluid The brake fluid level can be seen through a plastic sight glass in the brake reservoir . If the fluid is suffic ient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See pa[...]

92 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spon gy brake lever action. Bleed the system before operating the snowmobile. W ARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious in jury or death. Never operat[...]

93 MAINTENANCE Light s When servicing a halogen lamp, av oid touching the lamp with ba re fin- gers. Oil from your skin leaves a r esidue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol. Headlight Lamp Replacement 1. Peel back the foam shield covering the headlight assembly . 2[...]

94 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. T o maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. W ARNING! If you become aware of higher th an normal clutch engagement or an unusual vibration or shift pattern, see your dealer immedia tely . Do not opera[...]

95 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition and tension of the dr ive belt. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 1 15. Always carry a spare drive belt[...]

96 MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should b e 1 1/4 inches (3.2 cm). Drive Belt Adjustment 1. Loosen the 7/1 6-inch jam nu t on the be[...]

97 MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the dri ve belt after operati ng in reverse. The snowmobile must be stop ped after forward moti on to prevent damage to components during belt removal. Rotate the driven clutch counte r- clockwise 1/4 turn by hand to ensure forward engagemen t before attempti ng to rem[...]

98 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. 2. T o ensure satisfactory belt life, install belts so they oper- ate in the same direction of rotation by positioning the identification numbers so that you can read them. If required, separate the sheaves as outlined in the b[...]

99 MAINTENANCE T rack Maintenance T rack Inspection W ARNING! Broken track rods can cause a rotating track to come off the snowmobile, which could cause seri ous in jury or death. Neve r operate with a damaged track. Never rotate a damaged track under power . 1. Using a hoist, safely lift and support the rear of the snow- mobile of f the ground. 2.[...]

100 MAINTENANCE T rack Maintenance W ARNING! Moving p arts 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 measur ement or adjustments with the engin e running. T rack T ension T rack adjustment is critical for prop er handling. Always m[...]

101 MAINTENANCE T rack Maintenance T rack T ension 5. Check for specified slack between th e wear surface of the track clip and the plastic slider . Refer to the Track T ension Data Chart on page 100. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. 8. T ighten or loosen the track adjus ting screws to prov[...]

102 MAINTENANCE T rack Maintenance n T rack Alignment Periodically check that the track is centered and runnin g evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely su pport the rear of the snowmobile with the track of f the ground. 2. S tart the engine and apply a small amount of thrott le until[...]

103 MAINTENANCE S teering System Steering Inspection Each week, or before a long ride, ch eck all steering system fasteners and tighten if necessary . + + + +[...]

104 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment or adjust ment may cause loss of steerin g control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustmen t. See your Polaris deale r . W ith the handlebars in a straight ahead position, and with vehicle weight compressing [...]

105 MAINTENANCE S teering System n Ski Skags W ARNING! W orn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causi ng seri ous injury or death. See your dealer's studding chart fo r recommended skags. If you install longer or more aggressive carbide skags than the orig inal equipment, it may also be necess[...]

106 MAINTENANCE S teering System n Rail Slide Wear Measure slide thickness at several points along the rail. Have your dealer replace the slide when it's worn down to the top of the wear limit indicator groove ( + ). Do not operate the snowmobile if slide thickness measures les s than 7/16 I (1.1 cm). Rear Suspension Inspect the rear suspensio[...]

107 MAINTENANCE Fall T une-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer . His experienced and tr ained service technician will keep your snowmobile in pe ak operating condition. Matte Clear Coat Clea ning (if equipped) Matte finish products are prone to tr apping dirt, oils and other contami- nants. Polari[...]

108 MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Mainte- nance T able beg inning on page 7 4. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricat e clutch components, except the driven clutch sh aft bushing as outlined in the Master Repair[...]

109 MAINTENANCE T ransporting the Snowmobile Whenever the snowmobile is transported: 1. Be sure the fuel cap and oil cap are installed correctly . 2. T ie the snowmobile to the t ransp orting unit securely using suitable straps. 3. Remove the ignition key to prevent loss.[...]

110 POLARIS PRODUCTS Part N o. Description Engine L ubricant s 2870791 Fogging Oil (12 oz. Aerosol) 2875035 Premium 2-Cycle Semi-Synthetic Engine Oil (qt.) (break-in only) 2875036 Premium 2-Cycle Semi-Synthetic Engine Oil (gal.) (break-in only) 2877882 VES Gold Plus Synthetic 2-Cycl e Engine Oil (qt.) 2877953 VES Gold Plus Synthetic 2-Cycle Engine [...]

111 TROUBLESHOOTING Engine T roubleshooting Unless you have experience and training in two-cycle engine repair , see your dealer if technical problems arise. Problem Probable Ca use Solution Erratic engine oper- ating RPM during acceleration o r load variations Drive clutch binding • SEE YOUR DEALER. Driven clutch mal- function • SEE YOUR DEALE[...]

112 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Noise in drive system Broken drive clutch components • S EE YOUR DEALER. Bearing failure/ chaincase, jacks haft, or front drive shaft • S EE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed. Drive chain loose • Inspect and adjust (or repla[...]

113 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Engine turns but fails to start Faulty ignition • Install new spark plug(s). If engine still fails to start, check fo r spark. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is on. • Make sure the fuel tank co ntains fuel. •[...]

114 TROUBLESHOOTING Suspension T roubleshooting Problem Solution Rear suspension bottoms too easily • Adjust rear shock spring (see pages 39 and 47). • Change torsion spring to stif fer optional spring (see your dealer). • Revalve rear track s hock (see your dealer). Rides too stiff in rear • Check for binding suspension shafts and grease a[...]

115 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • W arm the engine at least five minutes. T ake the drive belt off the snowmobile in extremely cold weather and warm it up. Break snowm obile loo[...]

116 W ARRANTY Service and W a rranty Information Obt aining Service and W arranty Assist ance Read and understand the service data an d the Polari s warranty information con- tained in this manual. Cont act your Polaris dealer for replacement parts, service or warranty . Y o ur dealer receives freque nt updates on cha nges, modifications and tips o[...]

117 W ARRANTY Service and W a rranty Information Polaris Anti-Thef t System The Polaris anti-theft system (P A TS) monito ring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft . A. In addition to notifying th e proper law enforcement officials, the o[...]

118 W ARRANTY Limited W arranty Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, provides a ONE YEAR LIM- ITED W ARRANTY on all components of the Po laris snowmobile ag ainst defects in material or workmans hip. This warranty covers the parts and labor charges for repair or replacement of d efective parts that are cove red by this warranty .[...]

119 W ARRANTY Limit ations of warran ties and remedies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W AR- RANTIES NOT ST A TED IN THIS W ARRANTY . Some[...]

120 W ARRANTY Conditions and Exclusions In order to qualify for warranty , the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required veh icle Pre-Delivery Inspection, perfor m all applicable servic e bulle tins and have the consumer sign the PDI form prior to delivery ma[...]

121 W ARRANTY Polaris Second Y ear Engine Service Contract Second Y e ar Engine Service C ontract is standard on all el igible new and unused snow- mobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promot ion. Th e free Second Y ear E ngine Service Contract is honored by all authorized Polaris sno[...]

122 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Deale[...]

123 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions li mited warranty i s in addition to t he Polaris standard limite d warranty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S. Environm[...]

124 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive remedy for breac h of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REME DIES SET FOR TH IN THIS LIMITE D W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE T O ANY PERSON FOR BREACH O [...]

125 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners wit h an accurate log of maintenance and servi ces performed on the snowmobile. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.[...]

126 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

127 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

128 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 49 Air Pollution . . . . . . . . . . . . . . . . . . . 6 Avalanches . . . . . . . . . . . . . . . . . . . . 15 B Brake Lever Travel Inspec tion . . . . 55 Brakelight Replacem ent. . . . . . . . . . 93 Brakes . . . . . . . . . . . . . . . . . . 55, 90-92 Brake Fluid . . . . . . . . . . . [...]

129 INDEX F Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Fuel Filter . . . . . . . . . . . . . . . . . . . . . 81 Fuel Lines . . . . . . . . . . . . . . . . . . . . . 81 Fuel Pump . . . . . . . . . . . . . . . . . . . . . 81 Fuel Recomm endation . . . . . . . . . . . 63 Fuel Resis tor . . . . . . . . . . . . . . . . . . . 64 Fuel Sys[...]

130 INDEX S Safety Labels . . . . . . . . . . . . . . . . 21-23 Safety Sym bols . . . . . . . . . . . . . . . . . 8 Set-Up Guide, Suspension . . . . . . 38-41 Shock Lubrication, Re ar Shock . . . . 80 Shock Clicker, Rear S hock . . . . . . . 47 Shock Springs, Rear. . . . . . . . . . . . . 40 Shock Valving, IF S . . . . . . . . . . . . . 44 Side Pan[...]