Polaris 600 INDY manual

PMS 419 Snowmobile Owner's Manual for Maintenance and Safety 600 INDY 800 INDY[...]

IMPORT ANT NOTICE TO OWNER Modifications to this snowmobile are not recommended and may result in voided warranty covera ge. Please read the warranty section o f this manual carefully . W ARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precauti[...]

1 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www .polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products. ?[...]

2 The following are trademarks of POLARIS Industries Inc.: Copyright 2015 POLARIS Industries Inc. All information contained within this publication is based on th e latest product information at the time of publication. Due to constant improvements in the design and quality o f production components, some minor discrepancies may result between the [...]

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

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

6 INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education campaign. W e encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, inclu ding wildlife and vegetat ion. Snowmobile clubs and other or gan izat[...]

7 INTRODUCTION V ehicle Identification Numbers Record your snowmobile’ s identificati on 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 blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced. NO[...]

8 SAFETY Operator Safety The following signal words and symbol s appear througho ut this manual and on your vehicle. Y our safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol ind icates a potential personal injury hazard. DANGER A DANGER indicates a hazard[...]

9 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 91 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while dr[...]

10 SAFETY Operator Safety St ay Clear of T rack Y our snowmobile is propelled by a revolving track that must be partially 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 st ay clear of [...]

11 SAFETY Operator Safety Riding App arel Helmet W earing a helmet can prevent a severe head injury . Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania b[...]

12 SAFETY Operator Safety Disabled Operators Safe operation of this rider -active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Survival Prep aration For your safety , always ride in a group of other sno[...]

13 SAFETY Operator Safety Rider Cap acity This snowmobile is designed for a single rider only . Never carry a passenger on this snowmobile. Excessive Speed W ARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather . Always observe all state and local[...]

14 SAFETY Operator Safety Driver Awareness Slow down when traveling near po les, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wires on utility poles are also difficult to d[...]

15 SAFETY Operator Safety A valanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • T ake an av al anche class • 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[...]

16 SAFETY Operator Safety Ice and Snow Build-up W ARNING! Ice and snow build-up may in terfere with the steering of you r snowmobile, resulting in serious injury or death. Ke ep the und erhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right [...]

17 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the snowmobile and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the snowmobile and keep it from rolling freely downhill. W ARNING! When driving on long downhi[...]

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

19 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differen tly , and even the most docile conditions may become dangerous if operators drive improperly . If you're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under various conditions. Even seasoned drivers should spend [...]

20 SAFETY Operator Safety Windchill/T emperature Chart s The following information is provided to help you determine when temperatures become dangerous 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 emperature ( °[...]

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

22 SAFETY Safety Labels and Locations No Passenger W arning/Fuel Recommendation Label W ARNING This vehicle is designed for operator only . NO P ASSENGER FUEL RECOMMENDED 91+ OCT ANCE WITHOUT ETHANOL For maximum performance see decal on left hand side panel for proper gauge setting. 7178713 Reverse W a rning W ARNING Reverse operation, even at low [...]

23 SAFETY Safety Labels and Locations T rack W arning W ARNING S tay clear of track. Do not sit on seat back. Entanglement with the track o r a fall from seat back can result in severe injury or death. 7172519 Hot Surface W arning W ARNING Hot Surface Do Not T ouch Burns may result. Entire top of tunnel may be hot. Install only accessories specific[...]

24 SAFETY Safety Labels and Locations Operation W arning W ARNING • T o avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is mi ssing, contact a POLARIS dealer for a replacement. • This vehicle is capable of high sp eeds. Buried objects or uneven terrain can cause loss of con[...]

25 SAFETY Safety Labels and Locations Operation W arning • When operating with a passenger (on approved mode ls only) reduce speed and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle. • When operating on hard-packed snow , ice, or when crossing roads, steering and braking abi lity are greatly[...]

26 FEA TURES 9 14 5 6 7 13 12 2 1 3 4 11 10 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. Winds hield (access ory) 7. Handlebar 8. Fuel Filler C ap 9. Operator Seat 10. T aillight 1 1. Rear Bumper 12. Snow Flap 13. Suspension 14. T rack 15. Side Panel 16. Side Panel S trap 17. Side Panel Fasteners 16 15 8 17[...]

27 FEA TURES 1. Instrument Cluster (Dig ital/Analog Gauge shown) 2. Ignit ion Switch 3. Engine Stop Switch 4. Recoil St arter Handle 5. Brake Lever 6. Parking Brake Lock 7. Handlebar Gr ip Warmer Switch 8. Thum bwar mer Switch 9. T ool Kit/S torage Bag 10. Electronic Reve rse Button 1 1. MODE/SET Switch 12. Headlight Dimmer Switch 2 3 4 1 11 10 12 [...]

28 FEA TURES Adjust able Headlight s Move the headlight adjuster to the left to adjust the headlight beam upward. Move the adjuster to the right to adjust the beam downward. Cargo Storage The maximum weight capacity for the carg o area is 15 lbs. (7 kg). Always secure carg o before operating. Do not exceed the weight limit. Accessories POLARIS offe[...]

29 FEA TURES Fuel T ype Selection Whenever using ethanol, MTBE or other forms of oxygenated gasolines, the fuel type designation setting must be changed to “ETH” in the gauge. When using the reco mmended 91 non-ethanol gasoline, always select the “91-NON” setting. Whenever in doubt of your fuel pur chase, use the “ETH” setting as a safe[...]

30 FEA TURES Detonation Elimination T echnology (DET) The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate and you may notice decreased engine performance and RPM when the DET system is act[...]

31 FEA TURES Detonation Elimination T echnology (DET) The most likely causes of severe detonation are outlined in the troubleshooting table below . DET T roubleshooting Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol/non-ethano l fuel type setting V erify correct fuel type setting on gauge Low f[...]

32 FEA TURES Security System (Ignition Lock System) Y our snowmobile has an optional security function that can be activated by an authorized POLARIS dealer . If you have this feature activated, you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended. A locked system will limit engine speed to 3000 RPM, which pr[...]

33 FEA TURES Engine Overheat Indicators The over- temperature indicator in the instrument cluster will illuminate when the engine is overheating. T ake action to cool the engine. See Engine-Cooling Actions below . The indicator will flash when engine temperature reaches critical levels. S top the engine immediately . A flashing indicator indicates [...]

34 FEA TURES Instrument Cluster (Digit al/Analog) The instrument cluster contains the speedometer , indicator lamps, MODE button and rider information center . NOTICE: Certain products will damage the lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster . Immediatel y clean off any gasoline that splashes on the instru[...]

35 FEA TURES Instrument Cluster (Digit al/Analog) Indicator Lamp s Lamp Indicates Condition V ehicle S peed When standard mode is sel ected, speed displays in miles per hour . When metric mod e is selected, speed displays in kilometers per hour . Reverse This indicato r flashes when the transmission is in reverse. See page 87. High Beam The high be[...]

36 FEA TURES Instrument Cluster (Digit al/Analog) Rider Information Center The information center can be control led by either the MODE button on the instrument cluster or by the MODE/SET switch on the left handlebar . Setting change s must be made with the engine running or with the vehicle powered by an external DC power supply connector . Use th[...]

37 FEA TURES Instrument Cluster (Digit al/Analog) Rider Information Center Display Unit s (St andard/Metric) The display can be changed to disp lay either standard or metric units of measurement. While in the engine temperature display , press and hold the MODE button to change units. Odometer Mode The odometer records and displays th e distance tr[...]

38 FEA TURES Instrument Cluster (Digit al/Analog) Rider Information Center Security System (Ignition Lock Syste m ) This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer . If you have this feature activated, you can lock the ignition to prevent unauthorized use when leaving the snowmo[...]

39 FEA TURES Instrument Cluster (Digit al/Analog) Rider Information Center Security System (Ignition Lock Syste m ) First T ime Use of Y our Security System T ASK 3: Unlock the System 1. When the engine is running, the display will alternate between SECURE ON and ENTER. W ait until ENTER displays, then press and release SET to advance the digit. Wh[...]

40 FEA TURES Instrument Cluster (Digit al/Analog) Rider Information Center Security System (Ignition Lock Syste m ) Locking the System Wit h Y our Personal Security Code 1. S tart the engine and lock the parking brake. 2. Press and hold the MODE and SET buttons for 3 seconds, then release. SECURE OFF should be displayed. If not, repeat this step. 3[...]

41 FEA TURES Instrument Cluster (Digit al/Analog) Rider Information Center Security System (Ignition Lock Syste m ) Unlocking the System With Y our Personal Secur i ty Code 1. When the engine is running, the display will alternate between SECURE ON and ENTER. W ait until ENTER displays, then press and release SET to advance the digit. When the firs[...]

42 FEA TURES Instrument Cluster (Digit al/Analog) Rider Information Center Security System (Ignition Lock Syste m ) Changing to a New Security Code Any time you wish to change your curre nt security code to a new code, perform T ASK 2 through T ASK 4 of the First T ime Use of Y our Security System procedure beginning on page 38. Instead of using th[...]

43 FEA TURES Instrument Cluster (Digit al/Analog) Rider Information Center Diagnostic Display Mode The diagnostic display mode is for informational pu rposes only . Please see your POLARIS dealer for all major repairs. If a system error occurs, the check engine indicator will illuminate. Do not stop the engine if you want to view an err or code. Wh[...]

44 FEA TURES Instrument Cluster (MFD) The instrument cluster contains indicator lights and the rider information center . The information center can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the MODE/SET switch on the left handlebar . NOTICE: Certain products will damage the lens and other plastic surfaces.[...]

45 FEA TURES Instrument Cluster (MFD) Indicator Light s Check Engine Indicator This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning appears. Serious engine damage could result. See your dealer . See page 57 for diagnostic code definitions. Over-T emperature Indicator This indicator illuminates to aler[...]

46 FEA TURES Instrument Cluster (MFD) Rider Information Center The rider information center is located in the instrument cluster . The center displays vehicle speed, engine speed, odometer , resettable trip meters (2), total engine hours of operation, engine temperature and diagnostic display mode. Setting changes must be made with the engine runni[...]

47 FEA TURES Instrument Cluster (MFD) Rider Information Center 1. Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. T o change the display , see page 48. 2. Speed Display - The speed display area displays either vehicle [...]

48 FEA TURES Instrument Cluster (MFD) Rider Information Center Spe ed Display Area The speed display area displays either vehicle speed or engine speed. V ehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM). 1. T o change which item displays, first make su[...]

49 FEA TURES Instrument Cluster (MFD) 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 distance traveled by the vehicle since manufacture. Each trip meter records the distance traveled by the vehicle on a trip if the me[...]

50 FEA TURES Instrument Cluster (MFD) Rider Information Center St andard/Metric Display The odometer and temperature displays can be viewed in either standard or metric units of measurement. Both displays change if units are changed. The new settings will remain until changed by the operator . Change Method 1 1. Pr ess and r elease the MODE button [...]

51 FEA TURES Instrument Cluster (MFD) Rider Information Center Security System (Ignition Lock Syste m ) This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer . If you have this feature activated, you can lock the ignition to prevent unauthorized use when leaving the snowmobile unatten[...]

52 FEA TURES Instrument Cluster (MFD) Rider Information Center Security System (Ignition Lock Syste m ) First T ime Use of Y our Security System T ASK 3: Unlock the System 1. When the engine i s running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL to advance the digit. When[...]

53 FEA TURES Instrument Cluster (MFD) Rider Information Center Security System (Ignition Lock Syste m ) Locking the System Wit h Y our Personal Security Code 1. S tart the engine and lock the parking brake. 2. Press and hold the MODE and SEL buttons for 3 seconds, then release. SECURE OFF should be displayed. If no t, repeat this step. 3. W ait unt[...]

54 FEA TURES Instrument Cluster (MFD) Rider Information Center Security System (Ignition Lock Syste m ) Unlocking the System With Y our Personal Secur i ty Code 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. W ait until ENTER CODE displays, then press and release SEL to advance the digit. When the first [...]

55 FEA TURES Instrument Cluster (MFD) Rider Information Center Security System (Ignition Lock Syste m ) Changing to a New Security Code Any time you wish to change your curre nt security code to a new code, perform T ASK 2 through T ASK 4 of the First T ime Use of Y our Security System procedure beginning on page 38. Instead of using the factory de[...]

56 FEA TURES Instrument Cluster (MFD) Rider Information Center Diagnostic Display Mode The diagnostic display mode is for 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 diagnosti c code is active. Do not stop th[...]

57 FEA TURES Instrument Cluster (Digit al/Analog and MFD) 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 (injector , fuel pump, etc.), or the item has failed. Short-to-Gr ound: The wire is shorted to ground between the electronic control unit and the it[...]

58 FEA TURES Instrument Cluster (Digit al/Analog and MFD) Rider Information Center Diagnostic Display Code Definitions Diagnostic Codes Component Condition SPN FMI ECU Memory Checksum/CRC Error 628 13 Injector 1 (MAG) (Port Injector) Driver Circuit Open/Grounded 651 5 Driver Circuit Short to B+ 3 Injector 2 (PTO) (Port Injector) Driver Circuit Open[...]

59 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 necessary to provide the best riding experience for most riders. If all rear shock spring adjustments have been exhausted and rider weight is at the very high or very [...]

60 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 pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. T o change shock spring preload, gra[...]

61 THE PERFECT FIT Rear Suspension Adjustment s Rider weight, riding style, trail conditions, 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 suspension designs and adjustments involve a compromise, or trade-[...]

62 THE PERFECT FIT Rear Suspension Adjustment s Initial Spring Preload Setting (Sag Method) T o set up the rear suspension torsion 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. Tip : The rear bumper may need t[...]

63 THE PERFECT FIT Rear Suspension Adjustment s T orsion S pring Preload T o adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more ef fort. Different rat[...]

64 THE PERFECT FIT Rear Suspension Adjustment s Suspension Coupling On all POLARIS snowmobile rear su spensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move indepe ndently of each other . Rear suspension coupling links the movement of the front and re[...]

65 THE PERFECT FIT Rear Suspension Adjustment s Suspension Coupling Rear T o Front Coupling and the Rear Rear Scissor S top (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm. Adjusting the RRSS [...]

66 THE PERFECT FIT Rear Suspension Adjustment s Weight T ransfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. T o decrease weight transfer under acceleration (for improved corner - ing)[...]

67 THE PERFECT FIT T raction Product s Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and t o prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle s teering and control. See page 1 17. If your sn[...]

68 THE PERFECT FIT Handlebar Component Fastener T orques Component T orque Do not over-tight en IMPORT ANT : Moving a han dlebar component without first loosenin g its screws/set screws may cut groov es into the handlebar , makin g it difficult to secure the component. Do not move a handleba r component without first loosening its mounting screws/s[...]

69 THE PERFECT FIT Lef t Hand Control Alignment 1. Loosen the four control block mounting screws. CAUTION! T ake care to avoid damaging h and warmer/brake switch wires when moving components. 2. Mo ve the control block to the desired position. NOTE: If the control is loose and was inadvertentl y moved without loosening the screws, move the control [...]

70 THE PERFECT FIT Handlebar Adjustment s When adjusting handlebar position or angle, be sure the handlebar , brake lever and throttle lever operat e smoothly and do not hit the gas tank, windshield or any o ther part of the machine when turned fully to the left or right. If necessa ry , adjust the left and right hand controls. See page 69. Handleb[...]

71 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Item See Page Drive Belt Condi tion 109 S teering System 76 Recoil Rope 76 Coolant Level 101 Chaincase Oil Level 97 Injection Oil Level 84 Parking Brake L[...]

72 PRE-RIDE INSPECTIONS Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip. Item Check Page Suspension[...]

73 PRE-RIDE INSPECTIONS Before St arting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. W ARNING! Operating the vehicle with worn, damaged, or malfunctioni ng components could result in serio[...]

74 PRE-RIDE INSPECTIONS Before St arting the Engine Brakes Always check the following items for 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 inch (1.3 cm). A smaller distance indi- cates low brake fluid level or air in the hydraulic system. Refer to the [...]

75 PRE-RIDE INSPECTIONS Before St arting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary , such as when parked o n 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 Indicator Lock En[...]

76 PRE-RIDE INSPECTIONS Before St arting the Engine Steering System W ARNING! Ice and snow build-up may in terfere with the steering of you r snowmobile, resulting in serious injury or death. Ke ep the und erhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with [...]

77 PRE-RIDE INSPECTIONS S t art the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Before Starting the Engine beginning on page [...]

78 OPERA TION S t arting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is runni ng. 1. T urn the key to the ON position. 2. Pull the engine stop switch up to the RUN position. 3. If equipped with electric[...]

79 OPERA TION Break-In Period Engine Break-In Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine. Premix the first tank of fuel and fill the oil reservoir as outlined below . Oil added to the fuel and oil injection systems will provide the necessary[...]

80 OPERA TION Break-In Period Engine Break-In Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the fi rst three hours of use. V a ry the throttle openings and vehicle speeds to reduce friction on all close- fitting mach[...]

81 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 behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear su[...]

82 OPERA TION Fuel Gasoline is h ighly 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 refuelin g. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or allow open [...]

83 OPERA TION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher , with no ethanol. Although 87 octa ne fuel is usa ble, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing mor e than 10% ethanol. Never use E85 fuel in you[...]

84 OPERA TION 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 79 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 ope[...]

85 OPERA TION Engine St op Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly . Pull the switch up to the ON position to allow restarting. Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or [...]

86 OPERA TION Throttle Lever W ARNING! An improperly functionin g thro ttle lever may cause erratic snowmobile behavior a nd loss of control, wh ich could result i n serious injury or death. If the th ro ttle 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 igniti[...]

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

88 OPERA TION Electronic Reverse (PERC) Disengaging Reverse 1. S top the snowmobile and leave the engine idling. NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is runni ng. 2. Push the yellow reverse button for one s[...]

89 OPERA TION Daily St orage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 inch es (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&apos[...]

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

91 MAINTENANCE POLARIS Recommended Maintenance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 140. The recommended maintenance sche dule on your snowmobile calls[...]

92 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 riding conditions. When inspection reveals the need for rep lacement parts, always use genuine POLARIS parts, available from your POLARIS dealer . I - Inspect (clean, adjust, tighten, lu[...]

93 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 104 II II Brake Disc -- II II Parking Brakes 75 II II Brake System 74, 104 I Brake Fluid 105 I FUEL MANAG[...]

94 MAINTENANCE Periodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessar y) 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 Bolt T orq[...]

95 MAINTENANCE Hood and Side Panels The hood and side panels protect the operator from moving parts. Never operate a snowmobile with the side panels open or remove d. Always ensure that the hood and side panels are installed and securely latched before starting the engine. T o open a side panel, rotate the two 1/4-turn fasteners at the upper edges [...]

96 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 92 and before seasonal storage. When operating in heavy , wet snow conditions, lubricate every 500 miles (800 km). Lack of lubrication will adversely af fect y[...]

97 MAINTENANCE Lubrication Chaincase Oil Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning on page 91. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube. See page 126 for the part numbers of POLARIS products. Oil Level 1. Position th[...]

98 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendations A new engine can cause temporary sp ark plug fouling due to the preservative added during the assembly process. A void prolonged idle speeds, which cause plug fouling and carbonization. Refer to the specifications section for the specific spark plug to be used in your snowmobile. Change th[...]

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

100 MAINTENANCE Int ake Filters The intake filters on the left and right console limit snow ingestion into the intake system. When operating in loose powder snow , chec k the filters periodically to remove any accumulation of snow . Fuel Pump All fuel pump service must be performed by an authorized POLARIS dealer . Do not attempt to service the fue[...]

101 MAINTENANCE Cooling System Coolant POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water . See page 126 for the part numbers of POLARIS products. T o ensure that the coolant maintains its ability to protect the engine, we recommend that the system be complet[...]

102 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, conta[...]

103 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting. CAUTION! Hot exhaust system part s can cause burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine runnin[...]

104 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 74. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake pads. See your dealer . W ARNING! Brake failure d[...]

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

106 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. W ARNING! Operating the vehicle wi th 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[...]

107 MAINTENANCE Light s When servicing a halogen lamp, avoi d touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol. Headlight Lamp Replacement 1. Peel back the foam shield covering the headlight assembly . 2. R[...]

108 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 than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediatel y . Do not opera[...]

109 MAINTENANCE Clutch System Drive Belt Condition Periodically check the condition and tension of the drive belt. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 131. Always carry a spare drive belt. S[...]

110 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 be fore attempti ng to r[...]

111 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 injury or death. Never operate with a damaged track. Never rotate a damaged track under power . 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground. 2. Rot[...]

112 MAINTENANCE T rack Maintenance W ARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving part s. Never perform track measur ement or adjustme nts with the engine running. T rack T ension T rack adjustment is critical for proper handling. Always ma[...]

113 MAINTENANCE T rack Maintenance T rack T ension 5. Check for specified slack between the wear surface of the track clip and the plastic slider . Refer to the Track T ension Data Chart on page 11 2 . If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. 8. T ighten or loosen the track ad justing screws to pro[...]

114 MAINTENANCE T rack Maintenance T rack Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support t he rear of the snowmobile with the track of f the ground. 2. S tart the engine and apply a small amount of throttle until the[...]

115 MAINTENANCE S teering System Steering Inspection Each week, or before a long ride, check all steering system fasteners and tighten if necessary . x x x x[...]

116 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment o r adjustment may cau se loss of steering control, resulting in se rious injury or d eath. Do not attempt to change the ski alignment or toe adjustment. See your POLARIS dealer . If the steering feels heavy , or if the snowmobile seems to pull or dart to the side, ski [...]

117 MAINTENANCE S teering System Ski Skags W ARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing seri ous injury or death. See your dealer's studding chart fo r recommended skags. If you install lon ger or more aggressive carbide skags than the original equipment, it may also be necessary [...]

118 MAINTENANCE Battery (if equipped) W ARNING! Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death . Wh en removin g the battery , always disconnect the negative (black) ca ble first. When reinstalling the battery , always connect the negative (black) cable last. Battery Removal 1. Rem[...]

119 MAINTENANCE Battery (if equipped) Battery Charging The following battery char ging instructions apply only to the installation of a sealed battery . Read all instructions before proceeding with the installation of this battery . The sealed battery is already filled w ith electrolyte and has been sealed and fully char ged at the factory . Do not[...]

120 MAINTENANCE Fall 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 snowmobile in peak operating condition. T ransporting the Snowmobile Whenever the snowmobile is transported: 1. Be sure the fuel cap and oil cap are installed correctly . [...]

121 MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Maintenance T able beginning on page 92. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manua[...]

122 SPECIFICA TIONS 600 INDY Cap acities and Dimensions Body Style PRO-RIDE Rider Capacity 1 Coolant Capacity 5 qts. (4.7 l) Chaincase Oil Capacity 9 oz. (266.2 ml) Fuel T ank Capacity 1 1.5 gal. (43.5 l) Gearcase Oil Capa city N/A Oil Capacity 3.8 qts. (3.6 l) Height 48 in. (122 cm) Length 1 14 in. (289 cm) Designed W idth 48 in. (122 cm) Brake T [...]

123 SPECIFICA TIONS 600 INDY (Non-Electric St art Models) 600 INDY (Electric St art Models) Clutching Chart AL T ITUDE Meters (Feet) Drive Clutch Shif t Weight Drive Clutch Spri ng Driven Clutch Spr i ng Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 10-64 (1321585) 120/310 (7043681) RED/BLK (7043058) [...]

124 SPECIFICA TIONS 800 INDY Cap acities and Dimensions Body Style PRO-RIDE Rider Capacity 1 Coolant Capacity 5 qts. (4.7 l) Chaincase Oil Capacity 9 oz. (266.2 ml) Fuel T ank Capacity 1 1.5 gal. (43.5 l) Gearcase Oil Capa city N/A Oil Capacity 3.8 qts. (3.6 l) Height 48 in. (122 cm) Length 1 14 in. (289 cm) Designed W idth 48 in. (122 cm) Brake T [...]

125 SPECIFICA TIONS 800 INDY 800 INDY International Clutching Cha rt AL TITUDE Meters (Feet) Drive Cl utch Shift W eight Drive Clutch Spri ng Driven Clutch Spri ng Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 10-66 (1321584) 120/310 Black (7043681) RED/BLK (7043058) (64/42/36 ) L W (5135401) 23:39 72[...]

126 POLARIS PRODUCTS Part No. Description Engine L ubricant s 2870791 Fogging Oil (12 oz. Aerosol) 2878243 VES RACE 2-Cycle Engine Oil (qt./.95 l) 2878191 VES RACE 2-Cycle Engine Oil (gal./3.8 l) 2877882 VES 2-Cycle Oil (qt./.95 l) 2877953 VES 2-Cycle Engine Oil (2 qt./1.9 l) 2877883 VES 2-Cycle Engine Oil (gal./3.8 l) 2877884 VES 2-Cycle Engine Oi[...]

127 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 malfunction • SEE YOUR DEALER.[...]

128 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Noise in drive system Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, jackshaft, or front driveshaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed. Drive chain loose • Inspect and adjust (or replace).[...]

129 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 tank contains fuel. • Ice may b[...]

130 TROUBLESHOOTING Rear Suspension T roubleshooting Problem Solution Rear suspension bottoms too easily • Adjust torsion spring preload to achieve proper static sag (see page 62). • Change torsion spring to stif fer optional spring (see your dealer). • Revalve rear track shock (see your dealer). • Rotate RRSS to higher position (see page 6[...]

131 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 snowmobile loos[...]

132 W ARRANTY Service and W arranty Information Obt aining Service and Warranty Assist ance Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty . Y our dealer receives frequent updates on changes, modifications and tips on snowmobi[...]

133 W ARRANTY Limited W arranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a 12 MONTH LIMITED W ARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by [...]

134 W ARRANTY W arranty Coverage and Exclusions Limit ations of Warranties and Remedies This POLARIS Limited W arranty excludes any failures that are not ca us ed by a defe ct in material or workmanship. THIS W ARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not co ver acts of God, accidental damage, normal wear and tear [...]

135 W ARRANTY W arranty Coverage and Exclusions Limit ations of Warranties and Remedies Lubricants and Fluids 1. Mixing oil brands or using non-recomm ended oil may cause engine damage. W e recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-r ecommended lubricants or fluids is not covered by this warranty . [...]

136 W ARRANTY How to Obt ain W arranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer . When requesting warranty service you must present your copy of the W arranty Registration Form to the dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY .) POLARIS suggests tha[...]

137 W ARRANTY Exported Product s EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER VICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA TION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give au[...]

138 W ARRANTY U.S.A. EP A Emissions Limited W arranty This Emissions Limited W arranty is in a ddition to the POLARIS standard Limited W arranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehi cle is designed, built and equipped so it conforms with applicable U.S. Environmenta[...]

139 W ARRANTY U.S.A. EP A Emissions Limited W arranty The exclusive remedy for breach of this Limi ted W arranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRAN TY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF THI[...]

140 MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (32[...]

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

142 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 28 Air Polluti on . . . . . . . . . . . . . . . . . . . 6 Avalanches . . . . . . . . . . . . . . . . . . . . 15 B Battery . . . . . . . . . . . . . . . . . . 118-119 Charging . . . . . . . . . . . . . . . . 119 Installation . . . . . . . . . . . . . . . 118 Removal . . . . . . . . . . . [...]

143 INDEX H Handlebar Adjustments. . . . . . . . . . . 70 Handlebar Angle . . . . . . . . . . . . . . . . 70 Handlebar Component Fasteners . . . 68 Handlebar Control Adjustment, Left 69 Handlebar Posi tio n . . . . . . . . . . . . . . 70 Headlight Adjustment . . . . . . . . . . . . 28 Headlight Lamp Repla ce me n t . . . . 107 Hood Fasteners . . . [...]

144 INDEX S Security System (Ignition Lock) . . . 32 Shock Valving, IFS . . . . . . . . . . . . . 60 Side Panel Access . . . . . . . . . . . . . . 95 Side Panel Faste ners . . . . . . . . . . . . 76 Signal Words . . . . . . . . . . . . . . . . . . . 8 Ski Alignment . . . . . . . . . . . . . . . . 116 Ski Pressure . . . . . . . . . . . . . . . . . .[...]

PMS 419 For your nearest Polaris dealer , call 1-800-POLARIS (765-2747) or visit www .polaris.com Polaris Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No. 9925987 Rev 01 Printed in USA[...]