Polaris 50 Indy 2023 Owner's Manual
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Polaris 50 Indy 2023 Owner's Manual

Polaris 50 Indy 2023 Owner's Manual

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2023
For Maintenance and Safety
OWNER'S
MANUAL
550 Indy
550 Indy LXT
550 Indy Adventure
550 Switchback
550 Voyageur
Indy Evo
RMK Evo

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Summary of Contents for Polaris 50 Indy 2023

  • Page 1 2023 For Maintenance and Safety OWNER’S MANUAL 550 Indy 550 Voyageur 550 Indy LXT Indy Evo 550 Indy Adventure RMK Evo 550 Switchback...
  • Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code® with your smartphone.
  • Page 3 2023 Owner’s Manual 550 INDY 121 550 INDY LXT 550 INDY ADVENTURE 144 550 SWITCHBACK 144 550 VOYAGEUR 144 INDY EVO RMK EVO...
  • Page 4 Unless noted, trademarks are the property of Polaris Industries Inc. Allen® is a registered trademark of APEX BRANDS, INC. Loctite® is a registered trademark of Henkel Corporation. QR Code® is a registered trademark of DENSO WAVE INCORPORATED. BatteryMINDer® is a registered trademark of VDC Electronics Inc.
  • 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.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.
  • Page 6 SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

  • Page 7: Table Of Contents

    Specifications ....113 POLARIS Products ....129 Troubleshooting ....131 Warranty .

  • Page 9: Introduction

    This service can be performed by your authorized POLARIS dealer. You and your dealer must complete the registration form included with your snowmobile and forward it to us. This completed form is necessary to ensure warranty coverage.
  • Page 10 INTRODUCTION PRESERVATION OF THE ENVIRONMENT POLARIS is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment.
  • Page 11 INTRODUCTION VEHICLE IDENTIFICATION NUMBERS Record your snowmobile's identification numbers and key number in the spaces provided. NOTICE If installing an aftermarket tunnel wrap, do not cover the tunnel certification, tunnel VIN or emissions certification labels with the wrap. If the tunnel wrap doesn’t provide an opening for these labels, remove the section of wrap where the labels are located.
  • Page 12 Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank using the same identification number with one of your existing keys, so if both keys are lost, the ignition switch assembly must be replaced.

  • Page 13: 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 HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.
  • Page 15 EYE PROTECTION Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.
  • Page 16 • Fuel Deicer RIDER CAPACITY Some POLARIS snowmobiles are designed for a single rider only, while some are designed for up to two riders. A safety label on the vehicle indicates whether the vehicle is designed for a single rider or for two riders.
  • Page 17 SAFETY Variances in snow depth and/or water currents may result in uneven ice thickness. You may drown if you break through the ice. Never travel on frozen bodies of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the snowmobile, you and your cargo, together with any other vehicles in your party.
  • Page 18 SAFETY Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.
  • Page 19 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 20 SAFETY DRIVE BELT Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt can be performed by your dealer. WARNING Operation of the engine with the belt removed may result in injury or damage to the engine.
  • Page 21 SAFETY MANEUVERABILITY While much control and maneuverability is achieved through the steering system and skis, maximum control is achieved by the shifting of your body weight. Maneuverability will change based on rider weight and foot position on running boards. DRIVING RESPONSIBLY Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly.
  • Page 22 SAFETY WINDCHILL/TEMPERATURE CHARTS The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL CHART (°F) Wind Actual Thermometer Reading (°F) Speed -10 -15 -20 -25 -30 -35 -40 -45 in MPH Equivalent Temperature (°F) Calm -10 -15 -20 -25 -30 -35 -40 -45 -11 -16 -22 -28 -34 -40 -46 -52...
  • Page 23 If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
  • Page 24 WARNING • To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If manual is missing, contact a POLARIS dealer for a replacement. • This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control.
  • Page 25 SAFETY • Parking brake may relax when used for long periods. Do not leave brake engaged for more than five minutes. • Before starting the engine, check throttle, brake, and steering for proper operation. Make sure hood is latched. Be seated and in position to control the vehicle.

  • Page 27: Features

    FEATURES FEATURES COMPONENT LOCATIONS NOTICE The figures below are for reference only. Your model may differ slightly. Skis Operator Seat IFS Shock Nosepan Taillight Side Panel Front Bumper Rear Bumper Torsion Spring Hood Snow Flap Rear Track Shock Headlight Upper Control Arm Front Track Shock Windshield (accessory) Lower Control Arm...
  • Page 28 FEATURES ADDITIONAL COMPONENT LOCATIONS Instrument Cluster Parking Brake Lock Ignition Switch Handlebar Grip Warmer Switch Engine Stop Switch Thumb-warmer Switch Recoil Starter Handle Electronic Reverse Button Brake Lever Headlight Dimmer Switch Tool Kit/Storage Bag...
  • Page 29 3. Belt Removal Tool 4. Screwdriver 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 snowmobile. Use of unapproved parts and accessories may result in:...
  • Page 30 • Injury to self or others This applies to, but is not limited to the following areas: brakes, clutches, fuel systems, and exhaust systems. Exhaust systems are critical safety areas that must use approved POLARIS parts. Please see your POLARIS dealer for service.

  • Page 31: Gauge

    GAUGE GAUGE STANDARD INSTRUMENT CLUSTER Low Oil High Beam Low Battery Voltage Parking Brake Reverse NOTICE Certain products will damage the lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Immediately clean off any gasoline that splashes on the instrument cluster.
  • Page 32 GAUGE INDICATOR LAMPS INDICATOR CONDITION The low oil indicator light may flicker at times due to oil movement in the bottle, but when the light comes on and remains on, add the recommended oil before further operation. The low battery voltage indicator illuminates when the battery voltage is low.
  • Page 33 GAUGE RIDER INFORMATION CENTER The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine temperature and diagnostic display mode. Setting changes must be made with the engine running or with the vehicle powered by an external DC power supply connector.
  • Page 34 GAUGE SPEED DISPLAY AREA The speed display area displays either vehicle speed or engine speed. Vehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM). 1. To change which item displays, first make sure the information display area is set to display either engine speed or vehicle speed.

  • Page 35: The Perfect Fit

    THE PERFECT FIT THE PERFECT FIT FRONT SUSPENSION ADJUSTMENTS 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 low weight range for the stock spring, additional adjustments are possible to the IFS, Settings will vary from rider to rider, depending on rider weight, vehicle speed,...
  • Page 36 To adjust shock spring preload, grasp the spring retainer and rotate it. Some models are not equipped with IFS spring adjuster. Please see your POLARIS dealer for accessory options.
  • Page 37 Bogie wheel kits are available from your dealer. • POLARIS offers track kits for improved flotation in deep snow. See your dealer for assistance. Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.
  • Page 38 THE PERFECT FIT WARNING Allow a passenger to ride only on models equipped with a passenger seat. 1. Securely elevate and support the rear of the snowmobile to remove the weight from the suspension. 2. Use a tape measure to measure the spring installed length between the two spring retainers.
  • Page 39 THE PERFECT FIT 550 INDY MODELS REAR TRACK SHOCK SPRING (RTSS) SET-UP (Standard Spring) Measure spring length with suspension off the ground Rider Weight (including all riders, Model Installed Spring Length (rear gear, cargo, & accessories suspension off the ground) Shaded cells indicate factory settings.
  • Page 40 THE PERFECT FIT 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 the first measurement with no rider and with the rear suspension at full extension.
  • Page 41 THE PERFECT FIT This is only an initial setup, and final spring preload may vary based on rider preference and riding conditions. Accessory springs with a higher load rating are available for some models. Please see your dealer for availability. TORSION SPRING PRELOAD (121) To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool.
  • Page 42 THE PERFECT FIT LIMITER STRAP POSITION (SKI PRESSURE) Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter strap .
  • Page 43 THE PERFECT FIT SUSPENSION COUPLING (121 MODELS ONLY) On all POLARIS snowmobile rear suspensions, 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 independently of each other. Rear suspension coupling links the movement of the front and rear torque arms to each other.
  • Page 44 THE PERFECT FIT WEIGHT TRANSFER 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. To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position.
  • Page 45 THE PERFECT FIT High Medium Your dealer can help you with initial setup and additional setup instructions to help you achieve your optimum ride. A scissor stop tool is also available from your dealer.
  • Page 46 THE PERFECT FIT TRACTION PRODUCTS CARBIDE SKAGS A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control.
  • Page 47 THE PERFECT FIT HANDLEBAR COMPONENT FASTENER TORQUES COMPONENT TORQUE DO NOT OVER-TIGHTEN IMPORTANT: Moving a handlebar component without first loosening its screws/set screws may cut grooves into the handlebar, making it difficult to secure the component. Do not move a handlebar component without first loosening its mounting screws/set screws.
  • Page 48 THE PERFECT FIT LEFT HAND CONTROL ALIGNMENT 1. Loosen the four control block mounting screws. CAUTION Take care to avoid damaging hand warmer/brake switch wires when moving components. 2. Move the control block to the desired position. NOTICE If the control is loose and was inadvertently moved without loosening the screws, move the control block slightly to the left or right to relocate the pins.
  • Page 49 THE PERFECT FIT THROTTLE BLOCK ALIGNMENT CAUTION Take care to avoid damaging hand warmer/brake switch wires when moving components.  1. Slightly loosen the set screw on the bottom of the housing. 2. Move the control block to the desired position. 3.
  • Page 50 THE PERFECT FIT HANDLEBAR ADJUSTMENTS HANDLEBAR ANGLE  1. Securing the handlebar clamp bolts with an Allen wrench, loosen each of the four nuts (located on each bolt’s opposite end). CAUTION Take care to avoid damaging hand warmer/brake switch wires when moving components.

  • Page 51: Pre-Ride Inspections

    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 referenced pages. ITEM SEE PAGE Drive Belt Condition page 88 Steering System page 53 Recoil Rope page 54...
  • Page 52 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 SEE SECTION Check suspension mounting bolts for...
  • Page 53 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, contaminated, or malfunctioning components could result in serious injury or death.
  • Page 54 PRE-RIDE INSPECTIONS LEVER FEEL If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See the Brake Fluid section for details. WARNING Continued use of “spongy” brakes may cause a complete loss of brakes, which could result in serious injury or death.

  • Page 55: Steering System

    PRE-RIDE INSPECTIONS WARNING If the parking brake lever lock is partially or entirely engaged while riding, the brakes may overheat, resulting in brake damage. In extreme cases it could cause a fire, which could result in serious injury or death. Always ensure that the lever lock is completely disengaged before operating the snowmobile.

  • Page 56: 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, your POLARIS dealer can provide a replacement. START THE ENGINE AND CHECK Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation.

  • Page 57: Operation

    OPERATION OPERATION STARTING THE ENGINE  FULL CHOKE  1/2 CHOKE  CAUTION 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.
  • Page 58 OPERATION 8. After the engine starts, flip the choke toggle to the OFF position. If the engine slows or wants to stop, use intermittent choking to the HALF CHOKE position. 9. Before turning the engine off, operate the choke intermittently to draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen.
  • Page 59 -40° F (-40° C). NOTICE Use of any lubricants other than those recommended by POLARIS may cause serious engine damage. We recommend the use of POLARIS lubricants, or an equivalent product, for your vehicle.
  • Page 60 OPERATION NOTICE Serious engine damage can occur without the proper lubrication. Check the oil bottle level often during the first tank of fuel. If the oil level doesn't go down, contact your dealer or other certified technician immediately. DRIVE BELT BREAK-IN The break-in period for a new drive belt is 30 miles (48 km).
  • Page 61 FUEL RECOMMENDATION Your POLARIS engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There's a great deal of variability in the quality of the 87 octane gasoline available across the country, so we encourage the use of premium fuel when possible.
  • Page 62 Operating the snowmobile without adequate engine lubrication can result in serious engine damage. Always check the oil level when refueling. Add oil as needed. The oil bottle cap is vented to allow proper oil flow. See your POLARIS dealer for recommended replacement parts.
  • Page 63 NOTICE Making non-recommended adjustments could result in vehicle or engine damage as well as denial of warranty claims. Your Polaris dealer can assist with any carburetor adjustments. Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure.
  • Page 64 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 WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident.
  • Page 65 4. If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures. 5. If the engine doesn't start, your authorized POLARIS dealer can perform this service. Excessive freeplay in the throttle cable may cause the safety switch to activate, preventing the engine from starting.
  • Page 66 OPERATION Electronic reverse will activate only if the engine RPM is below 4000. CAUTION Engaging the starter when the engine is running WILL result in serious engine damage, especially if the engine is in reverse. Never engage the starter when the engine is running.
  • Page 67 OPERATION DAILY STORAGE 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 inches (10 cm) off the ground. Remove the key and cover the snowmobile.

  • Page 69: Maintenance

    Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions related service, however equivalent parts may be used for such service.
  • Page 70 Personal safety is critical when attempting to service or make adjustments to your snowmobile. If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfortable performing these tasks yourself, your authorized POLARIS dealer can provide any needed service.
  • Page 71 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. I - INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF NECESSARY)
  • Page 72 MAINTENANCE I - INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF NECESSARY) C - CLEAN, R - REPLACE, L - LUBRICATE FREQUENCY ITEM BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads (See page 85) Brake Disc Parking Brakes (See page 52) Brake System (See , page 85) Brake Fluid...
  • Page 73 MAINTENANCE I - INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF NECESSARY) C - CLEAN, R - REPLACE, L - LUBRICATE FREQUENCY ITEM Oil Lines Air Box Drain and Water Traps (See page 82) ELECTRICAL Auxiliary Shut-Off (See page 54) Throttle Safety Switch Ignition Switch Taillight (See page 54)

  • Page 74: Suspension Mounting Bolts

    MAINTENANCE I - INSPECT (CLEAN, ADJUST, TIGHTEN, LUBRICATE, REPLACE IF NECESSARY) C - CLEAN, R - REPLACE, L - LUBRICATE FREQUENCY ITEM CHASSIS Ski Toe Alignment Suspension Mounting Bolts Bolt Torques See your dealer every 1000 mi. (1600 km) for inspection Steering Fasteners Rear Suspension Fasteners Cooling Fan / Ducts / Bulkhead Vent...

  • Page 75: Rail Slide Condition

    Front Limiter Strap Rail Slide Condition (See page 100) Chaincase Oil BOLT TORQUE INSPECTION To maintain proper chassis performance, see your POLARIS dealer, or equivalent, for a bolt torque inspections every 1000 miles (1600 km). ITEM DESCRIPTION Engine Mounting Remove drive clutch and resonator for access to all...
  • Page 76 1. Pull the panel outward to release the tabs at the lower edge of the panel. NOTICE Removing the hood is not recommended. Any service requiring the removal of the hood should be performed by an authorized POLARIS dealer, or equivalent person. LUBRICATION...
  • Page 77 MAINTENANCE Lack of lubrication will adversely affect your ride and the life of the suspension. For more information about suspension lubrication and adjustments, see your POLARIS dealer. REAR SUSPENSION (144) REAR SUSPENSION (155)
  • Page 78 Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning pages. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube, or equivalent product.
  • Page 79 MAINTENANCE 4. Wipe the fill area with a clean cloth. 5. Reinstall the fill plug. TORQUE Fill Plug 6-10 ft-lbs (8-13 N·m) OIL CHANGE 1. Position the vehicle on a level surface. 2. Place a drain pan under the drain plug. Remove the drain plug. Allow the oil to drain completely.
  • Page 80 MAINTENANCE SPARK PLUG SPARK PLUG RECOMMENDATIONS It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning. Change the spark plugs every 2000-2500 miles (3200-4000 km) NOTICE A spark plug with a heat range too high will always cause engine damage if the...
  • Page 81 MAINTENANCE SPARK PLUG REMOVAL AND REPLACEMENT 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 Periodic Maintenance Table. The direction of the arrows indicates the direction of flow through the filter. FUEL PUMP All fuel pump service must be performed by an authorized POLARIS dealer. Do not attempt to service the fuel pump.
  • Page 83 MAINTENANCE FUEL FILTER / FUEL LINES This snowmobile is not equipped with an in-line fuel filter. The fuel pump uses a sock-type pickup filter located within the fuel tank. This filter should only require maintenance if debris or foreign material enters the fuel tank. An authorized dealer can provide service.
  • Page 84 MAINTENANCE NOTICE Operating the snowmobile with incorrect jetting can result in serious engine damage. Have your POLARIS dealer perform all carburetor adjustments to ensure all adjustments are done correctly. CARBURETOR ADJUSTMENTS The frequency at which the carburetors are synchronized or balanced is important.
  • Page 85 MAINTENANCE CLEANING PROCEDURE 1. Turn the fuel valve off. 2. Position a container or shop towel below the plug to catch drained fuel. 3. Slide the clamp away from the drain plug and remove the drain plug from the sediment tube. 4.
  • Page 86 MAINTENANCE DRIVE CHAIN TENSION Check drive chain tension weekly and before each long trip. 1. Remove the side panels. 2. Rotate the driven clutch counter-clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.
  • Page 87 MAINTENANCE BRAKES HYDRAULIC BRAKE INSPECTION Inspect the brake lever reserve before each use of the snowmobile. See page 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.
  • Page 88 POLARIS dealer for inspection and adjustment. BRAKE FLUID Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid, or an equivalent product. WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.
  • Page 89 MAINTENANCE During the bleeding procedure, keep the brake handle as level as possible. The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent. 1. Remove the brake master cylinder reservoir cover and gasket. 2.
  • Page 90 Do not operate the snowmobile until repairs have been made. All clutch maintenance and repairs can be performed by an authorized POLARIS dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. NOTICE The slider blocks and bushings of the 550 clutches are made of a material that may be damaged if lubricated.
  • Page 91 MAINTENANCE For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. DRIVE BELT DEFLECTION Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt and apply downward pressure while measuring at point.
  • Page 92 MAINTENANCE 1. Loosen the two 6 mm jam nuts using the Belt Tension Adjuster tool The adjuster tool is designed to allow access to the adjuster screw while holding the jam nut. NOTICE Both adjuster screws will need to be turned outwards (counter-clockwise) to decrease deflection.
  • Page 93 MAINTENANCE 4. After achieving the desired belt deflection, tighten the jam nut to specification while holding the adjuster screw stationary. 5. Turn the remaining adjuster screw inwards until it makes contact with the spacer washer. Turn screw inwards slightly, and then tighten jam nut to specification while holding the adjuster screw stationary.
  • Page 94 MAINTENANCE DRIVE BELT INSTALLATION 1. With the L-wrench inserted into the threaded hole and the sheaves in the open position, install the drive belt. Install the belt so that the numbers can be read correctly on the left side of the vehicle, or in the direction in which the belt was originally installed.
  • Page 95 MAINTENANCE TRACK LUBRICATION The slide rail needs snow for lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear. WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death.
  • Page 96 MAINTENANCE TRACK TENSION DATA CHART INDY (121) 10 lbs. (4.54 kg) 16 in. (40 cm) 7/8-1 1/8 in. ahead of rear (2.2-2.9 cm) idler shaft INDY EVO 10 lbs. (4.54 kg) 16 in. (40 cm) 7/8-1 1/8 in. ahead of rear (2.2-2.9 cm) idler shaft Tension adjustments should be made only after the track is warmed up and...
  • Page 97 MAINTENANCE 7. Loosen the locknuts 8. Tighten or loosen the track adjusting screws to provide equal adjustment on both sides of the track. 9. Repeat the measurement on the other side of the track. Check more frequently when the snowmobile is new. 10.
  • Page 98 MAINTENANCE 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. 2.
  • Page 99 Do not attempt to change the ski alignment or camber adjustment. Your POLARIS dealer can perform this service. If the steering feels heavy, or if the snowmobile seems to pull or dart to the side, ski alignment may need adjustment.
  • Page 100 MAINTENANCE 1. On some models, measuring ski toe must be done with the skis off the ground. Refer to the ski toe measurement table above. 2. If your model requires lifting the skis off the ground, safely elevate the front end of the snowmobile using a floor jack.
  • Page 101 MAINTENANCE WARNING Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. Check skags before each use of the snowmobile to ensure positive steering characteristics. Skags must be replaced when worn to half their original diameter.
  • Page 102 MAINTENANCE RAIL SLIDE WEAR For ease of inspection, all POLARIS rail slides have a wear limit indicator groove to indicate the minimum  permissible slide thickness Replace the rail slides if they are worn  to the top of the groove at any point along their length.
  • Page 103 MAINTENANCE BATTERY REMOVAL 1. Remove the right side panel to access the battery. See page 74. 2. Disconnect the black (negative) battery cable first. 3. Disconnect the red (positive) battery cable last. 4. Remove the battery. BATTERY INSTALLATION When installing a new battery, make sure it's fully charged prior to its initial use. Using a new battery that has not been fully charged can damage the battery and result in a shorter life.
  • Page 104 MAINTENANCE LEAD ACID CONVENTIONAL / DRY SHIPPED AGM BATTERY • The battery is NOT activated when packaged • A removable cap plugs / strip is located on top of the battery • Distilled water is added as required (Lead Acid only) •...
  • Page 105 MAINTENANCE 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 or greater using the battery charge ...
  • Page 106 MAINTENANCE OFF SEASON STORAGE NOTICE If the battery is stored during the winter months, electrolyte will freeze at higher temperatures as the battery discharges. The chart below indicates freezing points by specific gravity. SPECIFIC GRAVITY OF FREEZING POINT ELECTROLYTE 1.265 -75°...
  • Page 107 MAINTENANCE BatteryMINDer® 2012 AGM - 2 AMP battery charger 2830438 If you plan to store the vehicle for ONE month or longer, remove the battery from the vehicle and store the battery in a cool / dry location. Continue to maintain the battery with the 2 AMP charger and inspect the battery every 60 days.
  • Page 108 3. Treat the fuel in the fuel tank with the recommend amount of Polaris Carbon Clean. The recommended mixing ratio is outlined on the bottle label.
  • Page 109 Doing this drains the carburetors of fuel. FOGGING THE ENGINE Fogging the engine with Polaris fogging oil or similar commercial alternative is probably the most important storage step a rider can do to ensure the internal parts of their snowmobile’s engine do not rust and corrode during the storage...
  • Page 110 In addition, removing the battery allows access to other maintenance items, such as the chaincase chain tensioner bolt. 2. Connect a Polaris battery charger or equivalent commercially available charger to the battery. 3. Inspect the electrical connections and wire harnesses throughout the snowmobile.
  • Page 111 Do not spray metal protectant on the drive or driven clutches. LUBRICATE THE PIVOTS After washing the snowmobile, it is important to use Polaris Premium All Season grease to lubricate the various suspension / steering pivot points. Doing so forces any water accumulated within the joints out which prevents the formation of corrosion and rust.
  • Page 112 6. Using clean and dry shop towel, wipe down the exhaust pipe , silencer, and clutch sheaves. 7. Install the primary drive belt onto the clutches with the “Polaris” writing readable from the outside of the snowmobile. 8. Install the back-up (secondary) drive belt into the belt holder.
  • Page 113 Update the PIDD (if equipped) with the latest TRAILS update file. 20. Grease the rear suspension grease zerks with Polaris Premium All Season grease just enough to push out any water that may have accumulated in the suspension pivot points.

  • Page 115: Specifications

    SPECIFICATIONS SPECIFICATIONS INDY 121 INDY 144 INDY ADVENTURE 144 INDY LXT VOYAGEUR 144 CAPACITIES AND DIMENSIONS Body Style PRO-RIDE Coolant Capacity Rider Capacity 1 Rider Adventure Models: 2 Riders Chaincase Oil Capacity 8.96 oz (265 mL) Fuel Capacity 11.5 gal (43.5 L) Oil Capacity 3.05 qt (2.89 L) Gearcase Oil Capacity...
  • Page 116 Ignition Timing 15° BTDC @ 1600 RPM / 14° BTDC @ 6500 Spark Plug / Gap NGK® BR9ES / 0.028 in (0.70 mm) Recommended Engine Oil Polaris Blue 2-Cycle Semi-Synthetic Oil Recommended Fuel Octane Minimum 87 non-oxygenated CARBURETOR SETTINGS Main Jet...
  • Page 117 SPECIFICATIONS FEATURES Electric Fuel Gauge Low Oil Light Standard Parking Brake Standard Speedometer Standard Tachometer Standard CARBURETOR JETTING CARBURETOR JETTING – ALL MODELS *SHADED CELLS INDICATE FACTORY SETTINGS ALTI- AMBIENT TEMPERATURE TUDE METERS °F 0 TO ABO- (FEET) TO - TO +5 - 30 °C...
  • Page 118 SPECIFICATIONS CARBURETOR JETTING – ALL MODELS *SHADED CELLS INDICATE FACTORY SETTINGS ALTI- AMBIENT TEMPERATURE TUDE METERS °F 0 TO ABO- (FEET) TO - TO +5 - 30 °C -9 TO -1 TO ABO- TO - TO - TO - - 34 2400-30- Main Jet 00 (8000-...
  • Page 119 SPECIFICATIONS CLUTCHING AND GEARING INDY 121 ALTITUDE Drive Clutch Drive Clutch Driven Driven Helix Chaincase Meters Shift Weight Spring Clutch Gearing/ (Feet) Spring Pitch *Shaded cells indicate factory settings 0-600 2205307-43 (0-2000) gr (1 ea) 2205309-3.2 g (3 ea) 600-1200 (2000-4000) 1200-1800 2205308-21...
  • Page 120 SPECIFICATIONS LXT AND 144 MODELS ALTITUDE Drive Clutch Drive Clutch Driven Driven Helix Chaincase Meters Shift Weight Spring Clutch Gearing/ (Feet) Spring Pitch *Shaded cells indicate factory settings 0-600 2205307-43 (0-2000) gr (1 ea) 2205309-3.2 g (3 ea) 600-1200 (2000-4000) 18:42 1200-1800 2205308-21...
  • Page 121 SPECIFICATIONS INDY ADVENTURE 155 VOYAGEUR 155 CAPACITIES AND DIMENSIONS Body Style PRO-RIDE Rider Capacity 1 Rider (Voyageur) 2 Riders (Indy Adventure) Coolant Capacity Chaincase Oil Capacity 8.96 oz (265 mL) Fuel Capacity 11.5 gal (43.5 L) Oil Capacity 3.05 qt (2.89 L) Gearcase Oil Capacity Height 52 in (132 cm)
  • Page 122 15° BTDC @ 1600 RPM / 14° BTDC @ 6500 Spark Plug / Gap NGK® BR9ES / 0.028 in (0.70 mm) Recommended Engine Oil Polaris Blue Synthetic Blend 2-Cycle Oil Recommended Fuel Octane Minimum 87 non-oxygenated CARBURETOR SETTINGS Main Jet...
  • Page 123 SPECIFICATIONS CARBURETOR JETTING CARBURETOR JETTING 550 INDY ADVENTURE 155 / VOYAGEUR 155 * SHADED CELLS INDICATE FACTORY SETTINGS ALTI- AMBIENT TEMPERATURE TUDE METERS °F 0 TO ABO- (FEET) TO - TO +5 - 30 °C -9 TO -1 TO ABO- TO - TO - TO -...
  • Page 124 SPECIFICATIONS CARBURETOR JETTING 550 INDY ADVENTURE 155 / VOYAGEUR 155 * SHADED CELLS INDICATE FACTORY SETTINGS ALTI- AMBIENT TEMPERATURE TUDE METERS °F 0 TO ABO- (FEET) TO - TO +5 - 30 °C -9 TO -1 TO ABO- TO - TO - TO - - 34...
  • Page 125 SPECIFICATIONS INDY EVO RMK EVO CAPACITIES AND DIMENSIONS Body Style PRO-RIDE Rider Capacity 1 Rider Chaincase Oil Capacity 8.96 oz (265 mL) Fuel Capacity 10 gal. (37.85 l) 10 gal (37.85 L) Oil Capacity 3.05 qts. (2.89 l) 3.05 qt (2.89 L) Gearcase Oil Capacity Height 41 in (104.14 cm)
  • Page 126 Ignition Timing 15° BTDC @ 1600 RPM / 14° BTDC @ 6500 Spark Plug / Gap NGK BR9ES / .028 in (0.70 mm) Recommended Engine Oil Polaris Blue 2-Cycle Semi-Synthetic Oil Recommended Fuel Octane Minimum 87 non-oxygenated CARBURETOR SETTINGS Main Jet...
  • Page 127 SPECIFICATIONS FEATURES Electric Fuel Gauge Low Oil Light Standard Parking Brake Standard Speedometer Standard Tachometer Standard CARBURETOR JETTING CARBURETOR JETTING *SHADED CELLS INDICATE FACTORY SETTINGS ALTI- AMBIENT TEMPERATURE TUDE METERS °F 0 TO ABO- (FEET) TO - TO +5 - 30 °C -9 TO -1 TO...
  • Page 128 SPECIFICATIONS CARBURETOR JETTING *SHADED CELLS INDICATE FACTORY SETTINGS ALTI- AMBIENT TEMPERATURE TUDE METERS °F 0 TO ABO- (FEET) TO - TO +5 - 30 °C -9 TO -1 TO ABO- TO - TO - TO - - 34 2400-30- Main Jet 00 (8000- 10000) Pilot Jet...
  • Page 129 SPECIFICATIONS CLUTCHING AND GEARING INDY EVO ALTITUDE Drive Clutch Drive Driven Driven Helix Chaincase Meters Shift Weight Clutch Clutch Gearing/ (Feet) Spring Spring Pitch *Shaded cells indicate factory settings 0-600 2205308-21 gr (1 7044161 (0-2000) ea.) 112-247 2205309-3.2 g (8 600-1200 ea.) 1151-1120...
  • Page 130 SPECIFICATIONS RMK EVO ALTITUDE Drive Clutch Drive Driven Driven Helix Chaincase Meters Shift Weight Clutch Clutch Gearing/ (Feet) Spring Spring Pitch *Shaded cells indicate factory settings 0-600 2205308-21 gr (1 (0-2000) ea.) 7044188 2205309-3.2 g (8 600-1200 ea.) (2000-4000) 135-292 1200-1800 2205308-21 gr (1 (4000-6000)

  • Page 131: Polaris Products

    2882201 Oil - Polaris Blue SYN qt. (12) 2882202 Oil - Polaris Blue SYN gal. (6) 2882204 Oil - Polaris Blue SYN 2.5 gal. (2) Gearcase/Transmission Lubricants 2873105 SCL - Synthetic Chaincase Lubricant qt. (.95 l) 2873106 SCL - Synthetic Chaincase Lubricant gal (3.8 l)

  • Page 133: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ENGINE TROUBLESHOOTING Unless you have experience and training in two-cycle engine repair, your dealer can assist if technical problems arise. PROBLEM PROBABLE CAUSE SOLUTION Erratic engine Drive clutch binding Your dealer can perform operating RPM this service. during Driven clutch malfunction Your dealer can perform acceleration or...
  • Page 134 TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Noise in drive Broken drive clutch Your dealer can perform system components this service. Bearing failure/ Your dealer can perform chaincase, jackshaft, or this service. front drive shaft Drive belt surface flat Inspect and replace as spots needed.
  • Page 135 TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Engine turns but Faulty ignition Install new spark plug(s). If fails to start engine still fails to start, check for spark. If there's no spark, Your dealer can perform this service. No fuel to engine •...
  • Page 136 TROUBLESHOOTING PROBLEM PROBABLE CAUSE SOLUTION Incorrect throttle freeplay Your dealer can perform or faulty switch this service. Engine requires Poor fuel Replace with fresh winter more than normal fuel. pulls to start Not enough fuel getting to Your dealer can perform engine this service.
  • Page 137 TROUBLESHOOTING Front end pushes • Check for worn skags. • Check for binding front suspension shafts and steering components, grease all pivot points (elevate front of machine). • Increase IFS preload (if equipped). Steering is heavy • Make sure spindles and all steering components turn freely.
  • Page 138 TROUBLESHOOTING BELT WEAR/BURN DIAGNOSIS CAUSES SOLUTIONS Clutch malfunction Inspect clutch components. Your dealer can perform this service. Slow, easy clutch Use fast, aggressive throttle to engage clutch. engagement...

  • Page 139: Warranty

    Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual. Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you.
  • Page 140 REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage.
  • Page 141 WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS Limited Warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 142 TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW. HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer;...
  • Page 143 IF YOU PURCHASE FROM A PRIVATE PARTY: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
  • Page 144 IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have any questions.
  • Page 145 U.S.A. EPA EMISSIONS LIMITED WARRANTY This Emissions Limited Warranty is in addition to the POLARIS standard Limited Warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 146 POLARIS. Owners are responsible for performing the scheduled maintenance identified in the owner’s manual. POLARIS may deny warranty claims for failures that have been caused by the owner’s or operator’s improper maintenance or use, by...
  • Page 147 POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that you use only 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 149: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG 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. MILES SERVICE PERFORMED / DATE...
  • Page 150 MAINTENANCE LOG SERVICE PERFORMED / DATE HOURS TECHNICIAN COMMENTS...
  • Page 151 INDEX Fogging the Engine ....107 Lubrication ......109 Accessories .
  • Page 152 INDEX Fasteners, Hood and Side Panel. . . 54 Key Identification ..... . . 10 Fluid Change Chaincase ......77 Fluid Level Brake Fluid.
  • Page 153 Indy 121 ......113 Polaris Products ..... . 129 Indy 144 .
  • Page 154 INDEX Belt Removal Tool....27 Spark Plug Wrench ....27 Torsion Spring Preload .
  • Page 156 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Inc. Part No. 9940812 Rev 02 2100 Highway 55 Printed in USA Medina, MN 55340...

This manual is also suitable for:

550 indy lxt 2023550 indy adventure 2023550 switchback 2023550 voyageur 2023Indy evo 2023Rmk evo 2023

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