Polaris 600 Fusion manual

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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 dea th. PROPOSITION 65 W ARNING Snowmobile engines discharg e fuel and exhaust, which contain chemicals known to the State of California to c a u[...]

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 registere d trademarks of Pola ris Indus- tries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. M-10 is a registered trad emark of F AST Inc. Copyright 2005 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publicatio[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6[...]

4 INTRODUCTION V ehicle Identification Numbers Record your snowmo bile's identification numbers 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 Polaris key b lank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.[...]

5 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourage governm ents to adopt rigorous safety trai ning pro- grams that encourage protection of ou r environment, including wildlife and vegetation. Snowmobile clubs and o ther organizations are wo rking together to pro- te[...]

6 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 safe ty alert symbol , on your vehicle or in thi s manual, alerts you to the potential for injury . [...]

7 SAFETY Operator Safety Follow the recommended mainte nance program beginn ing on page 84 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your d ealer at specific mileage intervals. W ARNING Driving a snowmobile requires your full attenti on. DO NOT drink alcohol or use drugs or medications befor[...]

8 SAFETY Operator Safety Stay Clear of T rack Y our snowmobile is propelled by a revo lving track that must be part ially exposed for proper operation. Stay Clear of Engine Never attempt adjustments with the en gine running. T urn off the igni- tion, raise the hood, make the adju stment, secure shields and guards, secure the hood, and then restart [...]

9 SAFETY Operator Safety 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 un der many co nditions, the proper position is to be seated with both feet on the ru nning boards and both hands on th e handlebar grips for prop[...]

10 SAFETY Operator Safety Survival Preparation For your safety , always ri de in a gr oup of other sno wmobilers. 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 equipm ent that's appropriat e to the cond[...]

11 SAFETY Operator Safety Disabled Operators Safe operation of this rid er-active vehi cle requires good judgement and physical skills. Operators with cogn itive or physical disabilities have an increased risk of loss of control, wh ich could result in serious injury or death. Rider Capacity Y our Polaris snowmobile is designed for a single rider o[...]

12 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[...]

13 SAFETY Operator Safety Avalanches 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 sno[...]

14 SAFETY Operator Safety Ice and Snow Build-up Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full le ft and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstru cting the steering linkage. NOTE: If your snowmobile is equipped with RIDER SELE C[...]

15 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weig ht to the rear of the machine and reduce your speed to a minimum. Ap ply just enough throttle to keep the clutch engaged, allow ing the engine 's compression to help slow the machine and keep it fro m rolling freely downhill. W ARNING When driving on long downhil [...]

16 SAFETY Operator Safety Driving in Hilly T errain 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 machine to maintain proper balance and av oid possible roll-over . Slow down when reaching the c[...]

17 SAFETY Operator Safety Drive Belt Do not operate the engine wi th the drive belt removed. Any servicing that requires op eration without a belt must be performed by your dealer . Operation of th e engine with the belt remo ved may result in injury or damage to the engine. Intake Silencer Do not operate the engine with the intake silencer or filt[...]

18 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrica tion for the power slide suspension and, on liquid cooled mo dels, coo ling for the engine, adequate snow cover is a requirement for operation of your machine. Driving in too lit- tle snow will result in excessive wea r and damage to the slide rail, track and/[...]

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

20 SAFETY Operator Safety Windchill/T emperature Charts The following informatio n is provided to help you d etermine when tem- peratures become da ngerous for riding. WIND CHILL CHAR T ( _ F) WIND CHILL CHAR T ( _ C) Estimated Wind Speed in MPH Actual Thermometer Reading ( _ F) 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60 Equivalent T emperature ( _ F[...]

21 SAFETY Safety Decals and Locations W arning de cals have been placed on the snowmobile for you r protec- tion. Read and follow the instructions of the deca ls and other warnings on the snowmobile carefully . If any of the decals depicted in this man- ual dif fer from the decals on your snowmobil e, always read and follow the instructions of the [...]

22 SAFETY Safety Decals and Locations T rack W arning The track warning decal is on the rear of the tunnel: Stay clear of track. Do not sit on seat back. Entangle ment with the track o r a fall from seat back may result in severe injury or death. "No P assenger" W arning The "NO P ASSENGER" warning decal is on the console below [...]

23 SAFETY Safety Decals and Locations Reverse Warning The reverse warning decal is located on the console below the wind- shield: WARNING Reverse operation, even at lo w speeds, can cause los s of control resulting in serious injury or death. T o avoid loss of control, always: • Look behi nd before and while backing up. • Avoid sharp turns . ?[...]

24 SAFETY Safety Decals and Locations Operation W arning • T o avoid serious injury or death, read and un derstand all warnings and the Owner's Manual before oper ation. If manual is missing, con- tact a Polaris dealer for a replac ement. • This vehicle is capable of high speeds. Buried ob jects or uneven terrain can cause lo ss of control[...]

25 FEA TURES 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Snow Flap 7. Suspension 8. T rac k 9. Storage Compa rtment 10. Rear Bumper 11. T aillights 12. Nosepan 13. Front Bumper 14. Skis 5 8 2 3 4 7 6 14 12 13 1 9 9 10 11[...]

26 FEA TURES 1. F uel Filler Cap 2. Ignition Switch 3. Brake Leve r 4. RIDER SELECT 5. MFD Gau ge 6. Headlight Adjuster 7. Engine Stop Switch 8. Throttle Control 9. Hood Hold Down Straps 10. Recoil Starter Handle 11. Headlight Dimmer Switch 12. Park Brake 13. Handlebar Grip W armer Switch 14. Thumbwarmer Switch 15. Electro nic Reverse Butt on 16. M[...]

27 FEA TURES RIDER SELECT Adjusta ble Steering System The RIDER SELECT adjustable steering system allows you to adjust the handlebar position to f it your style of riding. Setting Position Riding Style Comfort 1, 2 Pull the system rearward to one of the first two positions for all-day trail riding comfort. Control 3, 4, 5 Move the system to one of [...]

28 FEA TURES RIDER SELECT Adjusta ble Steering System 1. Stop the snowmobile. 2. Press the release button and move the handlebar forward or rearward to the desired position. W ARNING Attempting to adjust the handlebar positi on while the snowmobile is moving could result in loss o f control and se riou s injury or death. Always stop the snowmobile [...]

29 FEA TURES F uel V alve The fuel valve is located under the hood. T urn the fuel valve of f when- ever the snowmobile is stored or parked. 1. T urn the valve clockwise to turn off the fuel supply . 2. T urn the valv e counter-clock- wise to turn on the fuel supply . Seat Storage Compartment Open or close the storage com- partments with the key . [...]

30 FEA TURES Detonation Elimination T echnology (D.E.T .) The DET system prevents damage to the engine from detonation while developing the maximum power of the en gine safely . A detonation sen- sor monitors the engine and respon ds to detonation by automatically reducing the engine timing. This can result in decreased engine RPM and performance. [...]

31 FEA TURES Detonation Elimination T echnology (D.E.T .) DET T roubleshooting Use this chart to determine causes an d solutions for detonation. If none of these conditions exists and the sensor remains activated, see your Polaris dealer for diagnosis. Sensor F ail-Safe The DET includes a sensor fail-safe system to prevent the engine from damage if[...]

32 FEA TURES Instrumentation MFD Component Identification Digital Display Identification Item 1 Analog Gauge 2 Digital Gauge 3 DET Indicator 4 Low Oil Indicator 5 High T emp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Ind icator Item 1 RPM or Speed Altitude (if equipp ed) Service Interval 2 Electrical System V o ltage Level 3 MAX - [...]

33 FEA TURES Instrumentation MFD Settings W ith the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch ( ✪ ) has a MODE but- ton (top) and a SET button (bottom). Standard vs. Metric The MFD will display either stan- dard or metric units of measurement. While viewing a screen that displays measu[...]

34 FEA TURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle thro ugh the thre e MFD programs: Per- formance, Engine and History . Each program will remain in the display until another is selected. NOTE: The analog will always display either MPH or engine RPM (whichev er setting is selected ) regardless of the dis play p[...]

35 FEA TURES Instrumentation MFD Digital Display Programs T rip Settings Tr i p 1 a n d Tr i p 2 ar e odometers used to check fuel mileage or to keep track of distance traveled. 1. T o reset a trip odometer to zero, enter the T rip 1 or T rip 2 display . 2. Press and hold the SET button for two seconds. T rip F automatically displays if the fuel le[...]

36 FEA TURES Instrumentation MFD Digital Display Programs Performa nce Program Clock Setting 1. While in the CLOCK display , press and hold the SET button for five seconds. 2. When the hour starts flashing press the SET switch once to advance one hour , or press and hold the SET button to advance the hour once every 0.2 sec onds. 3. Press the MODE [...]

37 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram The Engine Program automatically di splays the engine coolant tempera- ture, engine hours, electrical system voltage level and fuel level. On machines equipped with altimeter se nsor and ambient air temperature sensors, altitude and ambient air te mperature will display as ad[...]

38 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram Altitude (if equipped) The rider can calibrate th e altimeter for current atmospheric conditions . Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. NOTE: Press and hold the MODE switch for ten seconds to switch betwee n stan- dard and metric units of measu re- m[...]

39 FEA TURES Instrumentation MFD Digital Display Programs History Program The History Program automatically di splays electrical system voltage level and fuel level. While in the History mode, press the SET button to view maximum vehicle speed, maximum engi ne rpm or the current service interval set- ting. The gauge automatically logs the maximum s[...]

40 FEA TURES Instrumentation MFD Digital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders. When the logged hours reaches the designated service interval (set by the user), the gaug e provides a reminder that service is due. "SErVCE" will flash in the odometer area and "ENG[...]

41 FEA TURES Instrumentation MFD Battery Replacement If the clock function of the MFD isn't working properly , replace the battery . Replacement batteries are available from your dealer . 1. Remove the plenum from the under- side of the hoo d. 2. Locate the black battery compart- ment. It has a red wire and a bro wn wire with a white stripe. I[...]

42 FEA TURES Instrumentation MFD Battery Replacement 6. Install a new battery with fingers only . 7. Seal the end of the battery compar tment using high strength double- sided tape between the two compar t ment halves or high strength single-sided tape around the outside of the compartment. 8. Make sure the taped seam of the compartment faces the d[...]

43 THE PERFECT FIT IQ F ront Suspension Adjustments Independent F ront Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider , depending on rider weight, vehicle speed, riding style, and trail cond itions. W e recommend starting with factory settings a[...]

44 THE PERFECT FIT IQ F ront Suspension Adjustments F ront Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris de aler for assistance before attempt- ing to adjust preload. Increasing the spring preload too mu ch may adversely affect the han- dling of the snowmobile and the [...]

45 THE PERFECT FIT Rear Suspension Adjustments 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 adjustments involv e a compromise, or tr[...]

46 THE PERFECT FIT Rear Suspension Adjustments Suspension Performance Tips • Rider weight usually determines th e position at which the spring pre- load should be set. However, this may vary with riding style. W ith a little experimentation, each rider can find a preferred setup. These adjustments are easy to make, involv e very little time or ef[...]

47 THE PERFECT FIT IQ Rear Suspensi on Adjustments Initial Spring Preload Setting (Sag Method) T o set up the IQ rear suspension tor- sion spring preload, measure the distance between the ground and rear bumper . This is measurement X. T ake the first measurement with no rider and with the rear suspension at full extension. NOTE: The rear bumper ma[...]

48 THE PERFECT FIT IQ Rear Suspensi on Adjustments T orsion Spring T ension T o adjust rear torsion spring tension, rotate the three-position cam using the engine spark p lug tool. Adjust ment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more ef fort. Differen[...]

49 THE PERFECT FIT IQ Rear Suspensi on Adjustments Suspension Coupling On all Polaris snowmobile rear suspensi ons, there are two torque arms that control the mo vement of the rail beam. Prior to the advent of sus- pension coupling, thes e torque arms could mo ve independently of each other . Rear suspension coupling lin ks the movement of the fron[...]

50 THE PERFECT FIT IQ Rear Suspensi on Adjustments Rear T o F ront Coupling and the Rear Rear Scissor Stop (RRS S) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque ar m and limits the am ount of in depen- dent movement be tween the rear torque and the front torque arm. Adjusting the RRSS either all[...]

51 THE PERFECT FIT IQ Rear Suspensi on Adjustments W eight T ransfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scis sor stop (RRSS). The factory setting is the best for most trail riding conditions. T o decrease weight transfer under acceleration (for improved corner- [...]

52 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments The M-10 suspension has been design ed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. (1 1 kg) or more might require appropriate changes in settin gs. The following information has been compiled to assist yo u in tuning your M-10 suspension to its maxi- mum potenti[...]

53 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings 3. Subtract Y from X and you will ha ve the SAG setting (X - Y = sag setting. Example: 21 - 17 = 4). NOTE: The ideal amount of sag recomme nded for the F AST M-10 rear suspensi on is 3-4 inch es (8-10 cm). If the measured sag is incorrect, adjust the FRA [...]

54 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings FRA Position The FRA setting is the primary rear su spension adjustment . It will have the MOST ef fect on the rear suspension performance. T o adjust the FRA: 1. Refer to the initial set-up reference chart (located under the hood of your snowmobile and o[...]

55 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Static Sag and Ride Height Settings Rear Spring Preload If FRA position alone does not allow the setup of the pro per amount of sag, the center retainer of the rear track shock can be repla ced with optional retainers to adjust the prel oad and change the sag. See your Polaris dealer for as[...]

56 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Ski Pressure Ski pressure is set at the factory to deliver the optimum balance be tween ride and handling. If a rider prefer s more ski pressure for improved steering performance, adjustments can be made to the front limite r strap and front arm mount. 1. Determine if the rider prefers comf[...]

57 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Ski Pressure 4. There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole (1) increases ski pressure while the upper hole (2) decreases ski pressure. NOTE: By design, the BIASED COUPLE design of the M-10 suspen- sion displaces the rear ar m a[...]

58 THE PERFECT FIT Handlebar Adjustments Handlebar Position Use the RIDER SELECT feature to adjust handlebar position. See page 27. Handlebar Angle Follow these steps to adjust handlebar angle at the handle- bar block. 1. Remove the handleba r cover (1) to expose the handlebar and the four adjuster block bolts (2). 2. Using a 7/16 I wrench, loosen [...]

59 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 acce ssories on your Polaris snowmo bile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • V oiding of warranty • Injury[...]

60 THE PERFECT FIT T raction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. 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 [...]

61 THE PERFECT FIT T raction Products 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. Us e carbide skags with studded tracks to help maintain proper vehicle steering and control. See page 1 19. If your [...]

62 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on th e checklist for proper operation or condition before each use of the snowmob ile. Procedures are outlined on the ref- erenced pages. Look for a checkmark ( n ) on the refere nc ed pages to locate the pre-ride inspection items. Item See P age Drive Belt Condi tion 109, 111 Steering S[...]

63 PRE-RIDE INSPECTIONS Before Starting the Engine Read and Understan d Y our Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjo yable snowmobiling experience. n Throttle Lever The throttle and brake are the primar y controls of your snowmobile. Always make sure both are func[...]

64 PRE-RIDE INSPECTIONS Before Starting 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 br[...]

65 PRE-RIDE INSPECTIONS Before Starting the Engine n P ark Brake Lever Lock Use the park brake lever lock onl y when you want the machine to remain stationary; for ex ample, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Park Brake Lever Lock 3. Master Cylinder Reser- voir/ Cover 4. Fluid Level Indica tor Lock Eng[...]

66 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full le ft and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstru cting the steering linkage. NOTE: If your snowmobile is equip[...]

67 PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the snowmobile pr otects the operator from moving parts as well as aiding in sound emission con trol and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always en sure that the hood straps are in good condi tion an[...]

68 PRE-RIDE INSPECTIONS Start the Engine and Check n Engine S top Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. n Ignition Switch Make sure the engine st ops when the ignition switch is turned to OFF . n Te t h e r S w i t c h If your machine has a tether sw[...]

69 OPERA TION Starting the Engine Starting a Cold Engine (Manual Start) Do not depress the throttle until the engine starts . 1. T urn the fuel valve on. See page 29. 2. T urn the key to the ON position. 3. Pull the engine stop switch up to the RUN posit ion. 4. Flip the choke toggle to FULL ON. 5. Grasp the recoil ro pe han- dle and pull slowly un[...]

70 OPERA TION Starting the Engine Starting a W arm Engine 1. T urn the key to the ON position. 2. Pull the engine stop switch up to the RUN position. 3. Grasp the recoil rope handle and pull slowly until the recoil engages; then pull abruptly . If the engine does not start on the fi rst pull, slightly depress the throttle with your left hand (no mo[...]

71 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 75. Oil Recommendations This snowmobile is equipped with a variab le exhaust system (V ES). Engine lubrication comes from oil ad ded to the fuel and oil injection systems. Polaris recommends the use of VES II 2 Cycle Oil for this engine. S[...]

72 OPERA TION T rack W arm-Up Follow these steps to ensure proper warm-up of the engine, drive train and track. 1. Use an appropriate stand to securely sup- port the rear of the snowmobile at the rear bumper . The track should be about 4 I (10 cm) off the ground. 2. Start the engine and allow i t to warm up two to three minutes. 3. Depress the thro[...]

73 OPERA TION Fu e l W ARNING Gasoline is highl y flammable and explosive u nder 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 [...]

74 OPERA TION Fu e l For peak performance, Polaris recomm ends the use of 91 oc tane or higher fuel. Alt hough 87 octane fuel is usable, some engine p erfor- mance will be lost and fuel econ omy will decrease. Do not use fuel lower than 87 octane. Fu e l L e v e l The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level[...]

75 OPERA TION Oil n Low Oil Indicator Light The low oil indicator light will alert th e operator if the oil level is low . V isually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 71 for oi l recommendations. n Low Oil Level Maintaining the proper oil level w ill prevent system aeration and possi- ble loss[...]

76 OPERA TION Carburetion Proper carburetor adjustment is c ritical. A lean mixture (too muc h air , too little fuel) may result in piston bu rning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance. A lean mixture may be caused by thin gs like fuel[...]

77 OPERA TION Carburetion Jetting Guidelines Changes in altitude and temperatur e af fect air density , which is the amount of oxygen avai lable for combustion. In low ele vations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. The carbure tors are calibrated for a n a ltitude of [...]

78 OPERA TION n Engine Stop 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 throt[...]

79 OPERA TION Throttle Lever If the engine stops abruptly when the throttle lever is released: 1. T urn the ignition switch to OFF . 2. V isually inspect the throttle cable and carburetor to determine what caused the safety switch to activate. 3. T est the throttle lever by compressi ng and releasing it several times. The lever and cable must retur[...]

80 OPERA TION Emergency Stoppi ng The following chart lists methods for stopping the snowmobile in the event of an emergency . See page 78 for more information about the engine stop switch and throttle safety switch. SYSTEM WHA T IT DOES THROTTLE CONDITI ON Ignition Switch I nterrupts ignition circuit All Brake Slows jackshaft All Choke Floods engi[...]

81 OPERA TION Emergency Starting If the recoil starter system fails, an em ergency start strap is provided in the tool kit. 1. Open the hood . 2. Remove the left side panel. 3. Using the belt removal tool, follow the directions on the air box to relieve belt tension. 4. Starting at one of the tower struts, wind the strap counter- clockwise around t[...]

82 OPERA TION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine RPM is below 4000. Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear . 3. Push the yellow reverse button on the left-hand control for one sec- ond, then release. The engine will automat[...]

83 OPERA TION Daily Storage At the end of each ride, park the snowmo- bile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 I (10 cm) off the ground. Remove the key and cover the machine. To w i n g If the snowmobile becomes inope rable and must be towed, and if it isn&apos[...]

84 MAINTENANCE P olaris Recommended Mainte nance 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 138. The recommended maintenance schedul e on your snowmobi[...]

85 MAINTENANCE P eriodic Maintenance Interval T able The following chart is a guide based on average riding conditions. Y o u may need to increase fre quency based on ridi ng conditions. When inspection reveals the need for replacement parts , always use genuine Polaris parts, available from your Polaris dealer . I - Inspect (clean, adjust, tighten[...]

86 MAINTENANCE P eriodic Maintenance Interval T able Item See Pag e 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 103 II II Brake Disc -- II II Parking Brakes 65 II II Brake System 64, 103 I Brake Fluid 104 R FUEL MAN[...]

87 MAINTENANCE P eriodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Item See Pag e Fr eq u e n c y 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 Ste[...]

88 MAINTENANCE Lubrication F ront Suspension The front suspension and steering co mponents do not require lubrica- tion. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at 500 miles (800 km) initially , every 100 0 miles (1600 km) after that, and be fore off-seas on storage eac h year . Lack of lubricati[...]

89 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lightly with grease or oil. W ith the engine off, turn th[...]

90 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil leve l at the intervals outlined in the maintenance charts beginning on page 84. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). Change the chaincase oil after the first 500 miles (800 [...]

91 MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4 ) and drain the oil into a drain pan. Allow the oil to drain completely . 3. Install a new sealing washer on the drain plug. NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nick[...]

92 MAINTENANCE General Maintenance Spark Plugs A new engine can cause temporary spar k plug fouling du e to the preser- vative added during th e assembly process. A void prolo nged 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 mach ine. Change th[...]

93 MAINTENANCE General Maintenance Spark Plug Condition Spark plug condition is in dicative of engine operation. The spark plug firing end condition should be read after the engine has b een warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color . NOTE: Incorrect fuel mixture can often cause a[...]

94 MAINTENANCE General Maintenance Spark Plug Removal and Replacement 1. Remove the spar k plug cap. 2. Using the special wrench provided in the tool pouch, rota te the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plu g installation. 4. T orque to 18 -22 ft . lbs. (24 -30 Nm). 5. Reinstall the spark plug cap. Oil Lines [...]

95 MAINTENANCE General 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 . Fu e l P u m p All fuel pump service must be pe rformed by an authorized Polaris dealer . Do not attempt to serv[...]

96 MAINTENANCE General Maintenance Carburetor The number stamped in the en d of th e main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It's your dealer's responsibility to make sure the correct main jet is installed. Carburetor Adjustments The frequency at which th[...]

97 MAINTENANCE General Maintenance Carburetor W ater/Sediment T rap Most Polaris snowmobiles contain pa tented carburetor bowl water/sedi- ment traps located at the bottom of each carburetor . The trap, c onsisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination. Cleaning Procedure 1. T urn [...]

98 MAINTENANCE General Maintenance Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-gly col and distilled water . This mixture provides protection against freezing. Contact your dealer if greater protection is required. Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with wat[...]

99 MAINTENANCE General Maintenance Coolant High T emperat ure Indicator Light The high temperature indicator light wi ll illuminate when engine cool- ant temperature becomes too hot for safe continued operation of the engine. If you must drive your mach ine after the high temperature indi- cator light has come on, driv e slowly and stop frequently [...]

100 MAINTENANCE General Maintenance Bleeding the Cooling System 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. Perform the bleeding procedure when the engine is cold. 1. Remove the pressure cap and fill the coolant bottle w[...]

101 MAINTENANCE General Maintenance Exhaust System Check the exhaust system for wear or damage at approx imately 2000 miles (3200 km). T o inspect, all o w the engine and exhaust system to cool completely . Open the hood an d inspect the muf fler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.[...]

102 MAINTENANCE General Maintenance Drive Chain T ension Check drive chain tension weekly and before each long trip. T o obtain correct chain tension: 1. 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 . 2. Loosen the adjuster bolt[...]

103 MAINTENANCE General Maintenance n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 64. 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. See your dealer . Brake Components 1.[...]

104 MAINTENANCE General 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 [...]

105 MAINTENANCE General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brake system w ill cause spongy brake lever action. Bleed the system before operating the snowmobile. During the bleeding proc edure, keep the brake handle as leve l as possi- ble. The reservoir must be in this position to minimize the possibility of air en[...]

106 MAINTENANCE General Maintenance NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causin g a hot spot that will shorten the life of the lamp. If fingers do touch the bu lb, clean it with an alcohol- moistened towel. Headlight Bulb Removal 1. Remove the plenum covering from the headlight assembly . 2. Lift the [...]

107 MAINTENANCE General Maintenance T aillight/Brakelight Replacement 1. Open the rear storage compart- ment. 2. Reach into th e compartment an d locate the socket assembly above the door opening . 3. T urn the sock et counterclockw ise 1/4 turn. 4. Carefully pull the socket assembly away from the taillight. 5. Replace the bulb and rein stall the s[...]

108 MAINTENANCE General Maintenance Clutch System Periodically inspect clutch sheaves fo r damage , wear or belt resi due. T o maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. Clutch Alignment Offset Clutch alignment offset i s import ant for maintaining optimum perfor- mance. See your dealer for service an[...]

109 MAINTENANCE General Maintenance n Drive Belt Condition Periodically check the condition an d tension of the drive belt, and always carry a spare. Inspect the be lt for signs of excessive wear: frayed edges, missing cogs, cracks and excessiv e looseness. Replace the belt if any of these conditions exist. Se e Drive Belt T roubleshooting on page [...]

110 MAINTENANCE General Maintenance Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: T o ensure satisfactory belt life, install belts so they operate in th e same direction of rotation by positioning the identifica- tion numbers so that you can read them. If required, separate the sheaves as outlin[...]

111 MAINTENANCE General Maintenance 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 ap ply downward pres- sure while measuring at point 2. This measurement should b e 1 1/4 I (3.2 cm). Drive Belt Adjustment TEAM Clutch 1. Loosen the 7/16 I jam n[...]

112 MAINTENANCE General Maintenance To o l K i t A tool kit is included with each machine for emergency and routine maintenance. Always keep the tool kit with the snowmobile. F all T une-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer . His experienced and trained service technician will keep your machine in [...]

113 MAINTENANCE T rack Maintenance T rack Inspection 1. Using a hoist, safely lift and support the rear of the snow- mobile of f 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 foun[...]

114 MAINTENANCE T rack Maintenance T rack T ension T rack adjustment is critical for prop er handling. Always maintain cor- rect tension and alignment. NOTE: T ension adjustments should be ma de only after the track is warmed up and lim ber . 1. T urn the engine off. 2. Lift the rear of the machine and safely support it of f the ground. 3. Place th[...]

115 MAINTENANCE T rack Maintenance T rack T ension 4. Check for specified slack between th e wear surface of the tra ck clip and the plastic slider . Refer to the T rack T ension Data Chart on page 11 4 . If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the locknuts. 7. T ighten or loosen the track adju sting screws (4)[...]

116 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 support the rear of the ma chine with the track off the ground. 2. Start the engine and apply a smal l amount of throttle until the [...]

117 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, ch eck all steering system fasteners and tighten if necessary . ✪ ✪ ✪ ✪ ✪[...]

118 MAINTENANCE Steering System Ski Alignment W ith the handlebars in a st raight ahead position, and with veh icle weight compressing the suspension, measure from the straight e dge of the skis at the center of the sk i mounting bolt. The measurement between the skis at po int X should be 1/8 I to 1/4 I (3-6 mm) greater than the measurement at poi[...]

119 MAINTENANCE Steering System n Ski Skags Some models have one skag, others may have dual skags. Check sk ags before each use of the snowmobile to ensure positive steering character- istics. Skags must be replaced when wo rn to half their original diameter . NOTE: Carbide skags must b e replaced if any abno rmal wear or chip- ping is found. Skag [...]

120 MAINTENANCE Steering 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). Suspension Maintenance n Pre-Ride Suspens[...]

121 MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many componen ts. See page 124 for the part numb ers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, an d waxing the hood, chass[...]

122 MAINTENANCE Extended Storage Bearings Grease the jacks haft and drive sha ft clutch side bearings w ith Polaris Premium All-Season Grease or a simi lar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive b elt and store in a co ol dry locati on. Do not lubricate clutch components, except the driven clutch sh aft b[...]

123 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connecto rs. Be sure wiring harness is properly secured awa y from sharp edges, steering linkage, moving parts, and hot exhaust pa rts. T rack and Suspension Moderate track tension should be maintained during summer storag e. The machine should be sup[...]

124 POL ARIS PRODUCTS Pa r t N o . Description Engine Lubrica nts 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (ga l.) 2872[...]

125 TROUBLESHOOTING Engine T roubleshooting Unless you have experience and traini ng 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 DEAL[...]

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

127 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 for spark. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is on. • Use the choke. See page 69. • Make sure th[...]

128 TROUBLESHOOTING IQ Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper static s ag (see page 47). • Change torsion spring to stif fer optional spring (see your dealer). • Revalve rear tr ack s hock (see your dealer). Rides too stiff in rear • Check for bindi[...]

129 TROUBLESHOOTING M-10 Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Increase FRA position (see setup decal under hood for ini- tial posi tion. • Install appropriate optional ce nter retainer on rear track shock (see page 55). • Increase front track s hock coil spring preload. • Revalve rear track sho[...]

130 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 ma chine in extremely cold weather and warm it up. Break machine loose fro[...]

131 WA RRANTY Service and W arranty Information Obtaining Service and Warranty Assistance Read and understand the service data an d the Polari s warranty information con- tained in this manual. Contact your Polaris dealer for replacement parts, ser- vice or warranty . Y our dealer recei ves frequent updates on changes, modifications and tip s on sn[...]

132 W ARRANTY Service and W arranty Information Polaris Anti- Theft System The Polaris anti-theft system (P A TS) monitori ng program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polari s snowmobile owner reports t heft. A. In addition to notifyi ng the proper law enforcement officials, the o[...]

133 WA RRANTY 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 Polaris snowmobile against defects in material or workmanship. This warranty cove rs the parts and labor charges for r epair or replacement of defective parts that are cove red by th is warranty . [...]

134 W ARRANTY Limitations of warranties and remedies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AN D FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR T HER DISCLAIMS ALL EXPRESS W AR- RANTIES NOT ST A TED IN THIS W ARRANTY . Some[...]

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

136 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. The free Second Y ear Engine Service Contract is honored by all authorized Pola ris snow[...]

137 WA RRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIR ED 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. Deal[...]

138 MAINTENANCE L O G Present this section of your manual to your dealer each time your snow- mobile is serviced. This will prov ide you and future owners with an accurate log of maintenance and servi ces performed on the snowmobile. DA TE MILES (KM) TECHNICIAN SERVIC E PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 [...]

139 MAINTENANCE L OG DA TE MILES (KM) TECHNICIAN SERVIC E PERFORMED / COMMENTS[...]

140 INDEX A Accessories . . . . . . . . . . . . . . . . . . 59 Adjustable Headl ights . . . . . . . . . . 29 Adjustable Steering System . . . . 27-28 Air Pollution . . . . . . . . . . . . . . . . . . 5 Avalanches . . . . . . . . . . . . . . . . . . . 13 B Bearings . . . . . . . . . . . . . . . . . . . . 122 Brake Components. . . . . . . . . . . . 1[...]

141 INDEX I Ice and Snow Build- up . . . . . . . . . . 14 IFS . . . . . . . . . . . . . . . . . . . . . . . . . . 43 IFS Adjustment Options . . . . . . . . . 43 IFS Components . . . . . . . . . . . . . . . 43 Inadequate Snow Conditions . . . . . 18 Instrumentation . . . . . . . . . . . . . 32-42 Intake Filters . . . . . . . . . . . . . . . . . . 95[...]

142 INDEX S Storage, Daily . . . . . . . . . . . . . . . . 83 Storage, Extended . . . . . . . . . 121-123 Studs . . . . . . . . . . . . . . . . . . . . . . . 60 Survival Prep aration . . . . . . . . . . . 10 Suspension Coupling, IQ . . . . . . . . 49 Suspension Inspection, Pre-Ride . 120 Suspension Maintenance . . . . . . . 120 Suspension Performan[...]