Polaris 800 switchback assault Owner's Manual
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Polaris 800 switchback assault Owner's Manual

2011
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PMS 419
IMPORTANT NOTICE TO OWNER
Modifications to this snowmobile are not recommended
and may result in voided warranty coverage.
Please read the warranty section of this manual carefully.
800 SwitchBack
Assault
Snowmobile Owner's Manual
for Maintenance and Safety

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  • Page 1 PMS 419 IMPORTANT NOTICE TO OWNER Modifications to this snowmobile are not recommended and may result in voided warranty coverage. Please read the warranty section of this manual carefully. 800 SwitchBack Assault Snowmobile Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 PMS 419 For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9923248 Rev 01 Printed in USA *9923248...
  • Page 5 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.polarisindustries.com for the latest news, new product introduc- tions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 6 POLARIS, THE WAY OUT, SWITCHBACK and ASSAULT are registered trademarks of POLARIS Industries Inc. Copyright 2010 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 7: Table Of Contents

    POLARIS Products..... 100 Troubleshooting ..... . . 101 Warranty .

  • Page 9: Introduction

    INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations.

  • Page 10: Preservation Of The Environment

    POLARIS snowmobiles are engineered to conform to these SAE stan- dards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others.

  • Page 11: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your 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.

  • Page 12: Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

  • Page 13: Operator Safety

    Always check major and vital safety components before every ride. All POLARIS snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.

  • Page 14: Riding Position

    SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Do not stand on the plastic flap. WARNING! Serious injuries may result if NO STEP hands, feet, or clothing become entangled in the track.

  • Page 15: Riding Apparel

    Riding Apparel Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 16: Disabled Operators

    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 Preparation For your safety, always ride in a group of other snowmobilers.

  • Page 17: Rider Capacity

    SAFETY Operator Safety Rider Capacity This snowmobile is designed for a single rider only. Never carry a pas- senger on this snowmobile. Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile opera- tion and speed limits.

  • Page 18: Driver Awareness

    SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts.
  • Page 19 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • Take an avalanche class • Travel with experienced people • Travel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon.

  • Page 20: Driving On Slippery Surfaces

    SAFETY Operator Safety Ice and Snow Build-up WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering.

  • Page 21: Driving Downhill

    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.

  • Page 22: Drive Belt

    SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. NOTICE: Operation of the engine with the belt removed may result in injury or damage to the engine.

  • Page 23: Driving Responsibly

    SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile condi- tions 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 driv- ers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.
  • Page 24 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WINDCHILL CHART (_F) Wind Actual Thermometer Reading (_F) Speed -10 -15 -20 -25 -30 -35 -40 -45 Equivalent Temperature (_F) Calm -10 -15 -20 -25 -30 -35 -40 -45 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63...

  • Page 25: Clutch Warning

    If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are pro- vided by POLARIS at no charge. The part number is printed on the label. Clutch Warning...

  • Page 26: Reverse Warning

    SAFETY Safety Labels and Locations Reverse “No Passenger” Warning Warning “No Passenger” Warning Snowmobiles designed for a single rider only have a NO PASSENGER warning label on the console: WARNING This vehicle is designed for operator only. NO PASSENGER Reverse Warning The reverse warning label is located on the console: WARNING Reverse operation, even at low speeds, can cause loss of control...

  • Page 27: Hot Surface Warning

    WARNING Hot Surface Do Not Touch Burns may result. Entire top of tunnel may be hot. Install only accessories specifically approved for this model by POLARIS. Do not place clothing, bags or cargo on tunnel. Do not cover this label.

  • Page 28: Operation Warning

    • To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, con- tact a POLARIS dealer for a replacement. • This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control.
  • Page 29 SAFETY Safety Labels and Locations Operation Warning • When operating with a passenger (on approved models only) reduce speed and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle. • When operating on hard-packed snow, ice, or when crossing roads, steering and braking ability are greatly reduced.

  • Page 30: Features

    FEATURES 1. Nosepan 8. Operator Seat 2. Skis 9. Taillight 3. Front Bumper 10. Rear Bumper 4. Hood 11. Snow Flap 5. Headlight 12. Suspension 6. Windshield (accessory) 13. Track 7. Handlebar 14. Side Panel 15. Side Panel Fasteners...

  • Page 31: Features

    FEATURES 1. Fuel Filler Cap 12 11 2. Electronic Reverse Button 3. Brake Lever 4. Parking Brake Lock 5. Instrument Cluster 6. Ignition Switch 7. Engine Stop Switch 8. Throttle Control 9. Recoil Starter Handle 10. Handlebar Grip Warmer Switch 11.

  • Page 32: Features

    Down Accessories POLARIS offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only POLARIS parts and accessories on your POLARIS snowmo- bile. Use of unapproved parts and accessories may result in: •...

  • Page 33: Features

    FEATURES Fuel Resistor This snowmobile is equipped with a feature that allows the engine con- troller to select the proper operating software based on the type of fuel being used. See pages 57-58 for fuel information and recommendations. The ECU fuel designation connector must have the “NON-ETHANOL 160 OHM”...

  • Page 34: Features

    FEATURES Detonation Elimination Technology (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 activated.

  • Page 35: Features

    Low fuel/no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel filter or tank pick-up sock See your POLARIS dealer for service Alcohol-based fuel additive used with Do not add deicers or additives that Ethanol fuel...

  • Page 36: Features

    FEATURES Instrument Cluster Rider Information Center Check Engine High Beam Indicator Indicator Over- Park Brake Temperature Indicator Indicator Reverse Low Oil Indicator Indicator SELECT MODE Button Button The instrument cluster contains Mode/Set Switch indicator lights and the rider infor- mation center. The information cen- ter can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the MODE/...

  • Page 37: Features

    FEATURES Instrument Cluster Indicators 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 40 for diagnostic code definitions. Over-Temperature Indicator This indicator illuminates to alert the operator that the engine is over- heating.

  • Page 38: Features

    FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine tempera- ture and diagnostic display mode. Setting changes must be made with the engine running or with the vehi- cle powered by an external DC power supply connector.

  • Page 39: Features

    FEATURES Instrument Cluster 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. To change the dis- play, see page 36. 2.

  • Page 40: Features

    FEATURES Instrument Cluster Rider Information Center Speed Display Area The speed display area displays either vehicle speed or engine speed. Vehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM).

  • Page 41: Features

    FEATURES Instrument Cluster Rider Information Center Odometer/Engine Hour Display Area This area displays the odometer, Trip A meter, Trip 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 vehi- cle on a trip if the meter is reset before each trip.

  • Page 42: Features

    FEATURES Instrument Cluster Rider Information Center Standard/Metric Display The odometer and temperature displays can be viewed in either standard or metric units of measurement. Both displays change if units are changed. The new settings will remain until changed by the operator. Change Method 1 1.

  • Page 43: Features

    Diagnostic Display Mode The diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator is illuminated and a diagnostic code is active.

  • Page 44: Features

    FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.

  • Page 45: Features

    FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions. Diagnostic Codes Component Condition ECU Memory Checksum/CRC Error Injector 1 (MAG) (Port Injector) Driver Circuit Open/Grounded Driver Circuit Short to B+ Injector 2 (PTO) (Port Injector) Driver Circuit Open/Grounded Driver Circuit Short to B+ Knock Sensor 1 Voltage Too Low Ignition Coil Primary Driver 1 (MAG)

  • Page 46: The Perfect Fit

    THE PERFECT FIT Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take this measurement with no rider and with the rear suspension at full extension.

  • Page 47: Suspension Adjustments

    THE PERFECT FIT Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information. The following information is provided only as a guideline to be used for initial suspension set-up.

  • Page 48: Shock Compression Damping

    THE PERFECT FIT Suspension Adjustments Shock Compression Damping Compression damping can be adjusted at Stiffer Softer the front suspension and at the rear track shock. Make adjustments in 2-click incre- ments, then test ride. When adjusting the front suspension, always adjust both clickers equally.

  • Page 49: Handlebar Adjustments

    THE PERFECT FIT Suspension Adjustments Independent Front Suspension and Front Track Shock Spring Preload Factory settings, combined with user adjustments to the rear track shock spring, should be all that’s necessary to provide the best riding experi- ence for most riders. The primary adjustment for overall vehicle balance is torsion spring preload.

  • Page 50: Pre-Ride Inspections

    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 refer- enced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Item See Page Drive Belt Condition...

  • Page 51: Item See Page

    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 follow- ing items on a weekly basis or before any long trip. Item See Page Check suspension mounting bolts for tightness.

  • Page 52: Before Starting The Engine

    PRE-RIDE INSPECTIONS Before Starting 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. WARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death.
  • Page 53 PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2I (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.

  • Page 54: Parking Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1.

  • Page 55: Steering System

    Recoil Rope Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your POLARIS dealer for replacement.

  • Page 56: Start The Engine And Check

    PRE-RIDE INSPECTIONS Start 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 48.

  • Page 57: Operation

    OPERATION Starting 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 running. 1. Turn the key to the ON position. 2.
  • Page 58 Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. Oils may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All POLARIS oils are compatible with each other. Initial Fuel Premix Always premix fuel in 5-gallon (19-liter) increments in a separate fuel container.

  • Page 59: Oil Injection System

    NOTICE: Use of any lubricants other than those recommended by POLARIS may cause serious engine damage. We recommend the use of POLARIS lubricants for your vehicle.

  • Page 60: Slide Rail And Track Cooling

    OPERATION Track Warm-Up WARNING! A loose track or flying debris could cause serious injury or death. Stand 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.
  • Page 61 OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. •...

  • Page 62: Fuel Recommendation

    Never use deicers or additives containing methanol. POLARIS recommends the use of Carbon Clean Plus. See page 100 for the part numbers of POLARIS products. If you use fuel with up to 10% ethanol (sometimes labeled “oxygen-...

  • Page 63: Low Oil Level

    NOTICE: Operating the snowmobile without adequate engine lubrication can result in serious engine damage. Always check the oil level when refu- eling. Add oil as needed. The oil bottle cap is vented to allow proper oil flow. See your POLARIS dealer for recommended replacement parts.

  • Page 64: Engine Stop Switch

    OPERATION Engine Stop 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 valves do not return to the normal closed position.
  • Page 65 When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the snowmobile with the throttle safety switch disconnected. Return the snowmobile to an authorized POLARIS dealer for service as soon as possible.
  • Page 66 OPERATION Electronic Reverse (PERCt) WARNING 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 trans- mission if shifting is attempted when the engine is operating above idle speed. •...
  • Page 67 OPERATION Electronic Reverse (PERCt) 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 automatically reduce RPM and start a reverse rotation.

  • Page 68: Emergency Stopping

    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 60 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch...

  • Page 69: Daily Storage

    OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and sup- port it at the rear with an appropriate track stand. The track should be suspended approximately 4I (10 cm) off the ground. Remove the key and cover the snowmobile.

  • Page 70: Maintenance

    Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsi- ble for ensuring that the specified maintenance is performed. POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary.
  • Page 71 If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfort- able performing these tasks yourself, contact an authorized POLARIS dealer for service. NOTICE: Hot components can cause damage to plastic. Always make sure the exhaust system and engine have cooled before tipping the snowmo- bile on its side for service or inspection.

  • Page 72: Coolant Level

    The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine POLARIS parts, available from your POLARIS dealer. Item Frequency Page 150 mi.

  • Page 73: Auxiliary Shut-Off Switch (Engine Stop Switch)

    MAINTENANCE Periodic Maintenance Interval Table Item Frequency Page 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System 49, 82 Brake Fluid FUEL MANAGEMENT...

  • Page 74: Suspension Mounting Bolts

    I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Bolt Torque Inspection To maintain proper chassis performance, see your POLARIS dealer for a bolt torque inspection every 1000 miles (1600 km). Item Description Engine Mounting Bolts...
  • Page 75 To remove an open side panel, 1/4-Turn Fasteners pull the panel outward to release the tabs at the lower edge of the panel. Removing the hood is not recommended. Any service requiring the removal of the hood should be performed by an authorized POLARIS dealer.

  • Page 76: Rear Suspension

    MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS Premium All Sea- son Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 68 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

  • Page 77: Chaincase Oil

    67. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Syn- thetic Chaincase Lube. See page 100 for the part numbers of POLARIS products. Oil Level...

  • Page 78: Oil Filter

    MAINTENANCE Lubrication Oil Lines Inspect oil line condition every 1000 miles (1600 km). Oil Filter The oil filter is located at the side of the oil tank. Have your dealer change the oil filter and bleed the system annually or every 1000 miles (1600 km).

  • Page 79: Intake Filters

    Do not attempt to service the fuel pump. Fuel Filter/Fuel Lines See your POLARIS dealer for replacement of the fuel filter at the inter- vals outlined in the Periodic Maintenance Table beginning on page Contaminated or poor quality fuel will shorten the life of the fuel filter and result in poor engine performance.

  • Page 80: Spark Plugs

    MAINTENANCE Spark Plugs Spark Plug Recommendations A new engine can cause temporary spark plug fouling due to the preser- vative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your snowmobile.

  • Page 81: Spark Plug Inspection

    MAINTENANCE Spark Plugs Spark Plug Inspection Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.

  • Page 82: Cooling System

    Please see your POLARIS dealer. When adding or changing coolant, POLARIS recommends using Pre- mium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture.

  • Page 83: Engine Overheating

    This service must be performed when the engine is cold. Ask your POLARIS dealer to check the coolant when he performs the fall tune-up on your snowmobile.

  • Page 84: Bleeding The Cooling System

    MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly.

  • Page 85: Exhaust System

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

  • Page 86: Hydraulic Brake Inspection

    4. Brake Pad Material (Replace when thickness is less than 1/ 16I/1.5 mm). Excessive Lever Travel Hydraulic brakes are self-adjust- ing, but if excessive brake pad clearance develops, bring the snowmobile to an authorized POLARIS dealer for inspection and adjustment.

  • Page 87: Brake Fluid

    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 page 100 for the part numbers of POLARIS products.

  • Page 88: Bleeding The Hydraulic Brake System

    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. WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death.

  • Page 89: Headlight Lamp Replacement

    MAINTENANCE Lights When servicing a halogen lamp, avoid touching the lamp with bare fin- gers. 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.

  • Page 90: Clutch System

    POLARIS dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. NOTICE: The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated. Do not lubri- cate clutch bushings.

  • Page 91: Drive Belt Condition

    MAINTENANCE Clutch System n 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.

  • Page 92: Drive Belt Deflection

    MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (3.2 cm).

  • Page 93: Drive Belt Removal

    MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counter- clockwise 1/4 turn by hand to ensure forward engagement before attempting to remove the belt.

  • Page 94: Drive Belt Installation

    MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer cir- cumference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the break-in period.

  • Page 95: Track Inspection

    MAINTENANCE Track Maintenance Track Inspection WARNING! Broken track rods can cause a rotating track to come off the snowmobile, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snow- mobile off the ground.

  • Page 96: Track Tension

    MAINTENANCE Track Maintenance WARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment is critical for proper handling.
  • Page 97 MAINTENANCE Track Maintenance Track Tension 5. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7.

  • Page 98: Track Alignment

    MAINTENANCE Track Maintenance n Track 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 the rear of the snowmobile with the track off the ground.

  • Page 99: Steering Inspection

    MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check all steering system fasteners and tighten if necessary.

  • Page 100: Ski Alignment

    WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your POLARIS dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.

  • Page 101: Ski Skags

    4. Remove the rear end of the skag. 5. Reverse the steps to install a skag. n Rail Slide Wear For ease of inspection, all POLARIS rail slides have a wear limit indicator Minimum groove to indicate the min- Thickness imum permissible slide thickness.

  • Page 102: Transporting The Snowmobile

    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 components. See page 100 for the part numbers of POLARIS products. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, side panels, chassis, and plastic parts.

  • Page 103: Controls And Linkage

    MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Mainte- nance Table beginning on page 68. 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 Manual.

  • Page 104: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2875035 Premium 2-Cycle Semi-Synthetic Oil (qt./.95 l) (break-in only) 2875036 Premium 2-Cycle Semi-Synthetic Oil (gal./3.8 l) (break-in only) 2877882 VES Gold Plus 2-Cycle Oil (qt./.95 l) 2877953 VES Gold Plus 2-Cycle Engine Oil (2 qt./1.9 l)

  • Page 105: Troubleshooting

    TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine oper- Drive clutch binding • SEE YOUR DEALER. ating RPM during Driven clutch mal- •...
  • Page 106 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch • SEE YOUR DEALER. system components Bearing failure/ • SEE YOUR DEALER. chaincase, jackshaft, or front drive shaft Drive belt surface • Inspect and replace as needed. flat spots Drive chain loose •...
  • Page 107 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails Faulty ignition • Install new spark plug(s). If engine to start still fails to start, check for spark. If there's no spark, SEE YOUR DEALER. No fuel to engine •...

  • Page 108: Suspension Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension • Refer to the suspension adjustment and set-up information bottoms too easily beginning on page 42. • Revalve rear track shock (see your dealer). Rides too stiff in rear • Refer to the suspension adjustment and set-up information beginning on page 42.

  • Page 109: Drive Belt Troubleshooting

    TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • Warm the engine at least five minutes. Take the drive belt off the snowmobile in extremely cold weather and warm it up.

  • Page 110: Warranty

    Your dealer receives frequent updates on changes, modifi- cations and tips on snowmobile maintenance, which may supersede informa- tion contained in this manual. Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you.
  • Page 111 B. Owners must provide their name, address, telephone number and the model and serial number of stolen machines. POLARIS warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. POLARIS warranty will aid in notifying the proper owner when a unit is recovered.

  • Page 112: Limited Warranty

    POLARIS' control. This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the snowmobile.

  • Page 113: Engine Oil

    How to Obtain Warranty Service If your snowmobile requires warranty service, you must take it to a POLARIS dealer authorized to repair POLARIS snowmobiles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (The cost of transportation to and from the dealer is YOUR responsibility).
  • Page 114 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 vehi- cle Pre-Delivery Inspection, perform all applicable service bulletins and have the con- sumer sign the PDI form prior to delivery may void the warranty.
  • Page 115 You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and...
  • Page 116 How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle.
  • Page 117 This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 118 POLARIS dealer to perform any service that may be necessary for your vehi- cle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 119: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM) 150 mi.
  • Page 120 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 121 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 122: Index

    INDEX Accessories ....28 Display, Standard/Metric..38 Air Pollution ....6 Drive Belt Adjustment .
  • Page 123 Playback Function ....37 Ice and Snow Build-up ... 16 Polaris Products and Part Numbers 100 Inadequate Snow Conditions ..16 Pre-Ride Checklist .
  • Page 124 INDEX Side Panel Fasteners ... . 51 Taillight/Brakelight Replacement . . . 85 Signal Words ....8 Throttle Lever .

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