Polaris 600 RMK - Manuals

6 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 veg...

7 INTRODUCTION Vehicle Identification Numbers Record your snowmobile's identification numbers and key number in the spaces provided. 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 lo...

8 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 symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal inju...

9 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 79 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 alco...

10 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 hands, feet, or clothing become entangled in the track. Be alert when riding,...

11 SAFETY Operator Safety 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 established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. ...

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 Preparation For y...

13 SAFETY Operator Safety Rider Capacity This snowmobile is designed for a single rider only. Never carry a passenger 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 incleme...

14 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. Guy wi...

15 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 beaco...

16 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 ...

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 do...

18 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. Intake Silencer Do no...

19 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, 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...

20 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL CHART (°F) WINDCHILL CHART (°C) Wind Speed in MPH Actual Thermometer Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 ...

21 SAFETY Safety Labels and Locations Warning 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 labels depicted in this manual differ from the labels on your snowmobile, always r...

22 SAFETY Safety Labels and Locations “No Passenger” Warning Snowmobiles designed for a single rider only have the NO PASSENGER warning label on the lower left side of the console: WARNING This vehicle is designed for operator only. NO PASSENGER Reverse Warning The reverse warning label is located o...

23 SAFETY Safety Labels and Locations Track Warning The track warning label is on the rear tunnel: WARNING Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. Hot Surface Warning The hot surface warning is on the re...

24 SAFETY Safety Labels and Locations Operation Warning The operation warning label is also located on the console. 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. ...

26 FEATURES 8 13 5 6 7 12 11 2 1 3 4 10 9 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. Windshield (accessory) 7. Handlebar 8. Operator Seat 9. Taillight 10. Rear Bumper11. Snow Flap12. Suspension13. Track14. Side Panel15. Side Panel Fasteners 15 14

28 FEATURES Storage Bag/Tool Kit A storage bag and tool kit is located under the left side panel between the oil bottle and console. Cargo Storage Never hang heavy items or fuel containers from the rear of the tunnel. Cargo may be stowed only under the seat and as far forward as possible immediately...

29 FEATURES QUICKDRIVE Belt The QUICKDRIVE drive system (if equipped) utilizes a drive belt that exhibits extraordinary performance and service life when the belt is handled properly before and during installation. Improper handling of this belt can result in a shortened service life. Inspect and ch...

30 FEATURES 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: • Non-compliance with government/industry requiremen...

31 FEATURES Fuel Type 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 recommended 91 non-ethanol gasoline, always select the “91-non” setting. Whenever in doubt of your fuel purchas...

32 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 engin...

33 FEATURES Detonation Elimination Technology (DET) The most likely causes of severe detonation are outlined in the troubleshooting table below. DET Troubleshooting Security System (Ignition Lock System) Your snowmobile has an optional security function that can be activated by an authorized POLARIS...

34 FEATURES Instrument Cluster 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 or console. NOTICE: Certain produ...

35 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 48 for diagnostic code definitions. Over-Temperature Indicator ...

36 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 temperature and diagnostic display mod...

37 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 display, see page 38. 2. Speed Display - The sp...

38 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). 1. To c...

39 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 trave...

40 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 ...

42 FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) First Time Use of Your Security System Perform all tasks in the order shown if you wish to activate and use the optional security system. TASK 1: Activate the security system See your authorized POLARIS de...

44 FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Locking the System With Your Personal Security Code 1. Start 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. I...

45 FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Unlocking the System With Your Personal Security Code 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL ...

46 FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Changing to a New Security Code Any time you wish to change your current security code to a new code, perform TASK 2 through TASK 4 of the First Time Use of Your Security System procedure beginning on page...

47 FEATURES Instrument Cluster Rider Information Center 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 di...

48 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 co...

50 THE PERFECT FIT Suspension Adjustments Factory settings, combined with user adjustments to the rear track shock spring (RTSS), should be all that’s necessary to provide the best riding experience for most riders. The primary adjustment for overall vehicle balance is RTSS preload. Perform this adj...

51 THE PERFECT FIT Suspension Adjustments For riders who weigh 160-220 lbs. (73-100 kg), test ride at factory settings, then make fine-tuning adjustments. See page 52. For riders outside the 160-220 lbs. (73-100 kg) weight range, adjust the factory-set preload to the following installed lengths as a...

52 THE PERFECT FIT Suspension Adjustments Fine-Tuning Your Suspension Set-Up The primary adjustment for overall vehicle balance is RTSS preload. Adjust the factory-set preload to the recommended setting for your weight and then test ride. Additional minor adjustments can then be made to the spring p...

53 THE PERFECT FIT Suspension Adjustments Shock Compression Damping (RMK/ASSAULT RMK) The primary adjustment for overall vehicle balance is RTSS preload. Perform this adjustment first. See page 50. After adjusting RTSS preload to your satisfaction, compression damping adjustments can be made to cont...

54 THE PERFECT FIT Suspension Adjustments Independent Front Suspension and Front Track Shock Spring Preload (RMK/PRO-RMK) Factory settings, combined with user adjustments to the rear track shock spring, should be all that’s necessary to provide the best riding experience for most riders. The primary...

55 THE PERFECT FIT Handlebar Adjustments Handlebar Position (if equipped) 1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver. 2. Adjust the handlebar forward or rearward to the desired position. 3. Tighten the bolts. Handlebar Angle 1....

57 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 bef...

58 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 ...

59 PRE-RIDE INSPECTIONS Before Starting the Engine 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 1/2 inch (1.3 cm). A smaller distance indicates low brake fluid level ...

60 PRE-RIDE INSPECTIONS Before Starting the Engine 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. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylin...

61 PRE-RIDE INSPECTIONS Before Starting the Engine Steering System 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...

62 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. S...

63 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. Pull the engine stop switch up to t...

64 OPERATION Starting the Engine Restarting an Engine If the rider stops the engine by pushing the engine stop switch down, restart the engine using the normal starting procedure. If the engine fails to start using the normal procedure: 1. Push the engine stop switch down to the OFF position. 2. Tur...

65 OPERATION 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 ...

66 OPERATION 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 first three hours of use. Vary the throttle openings and vehicle speeds...

67 OPERATION Break-In Period Drive Belt/QUICKDRIVE Belt Break-In The length of the break-in period varies depending on the type of drive system. The break-in period for a new drive belt is 30 miles (48 km). The break-in period for a new QUICKDRIVE belt is 100 miles (160 km). • Vary the throttle posi...

68 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 th...

70 OPERATION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher, with no ethanol. Although 87 octane fuel is usable, 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...

71 OPERATION 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 65 for oil recommendations. 1. Immediately stop the engine if the low oil indicator light comes on. 2. Open the left side panel. 3. View the oil level in the...

72 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 fro...

73 OPERATION Throttle Lever WARNING! An improperly functioning throttle lever may cause erratic snowmobile behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. If the engine stops abruptly when the throttl...

75 OPERATION Electronic Reverse (PERC) 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 second, then release. The engine will automatically reduce RPM and start ...

76 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 72 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft ...

77 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. Towing For your safety, do not ...

78 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 Your snowmobile is equipped at the time of sale with an emission control information (ECI) lab...

79 MAINTENANCE POLARIS Recommended Maintenance Program To 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 135. The recommend...

80 MAINTENANCE Periodic Maintenance Interval Table 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 d...

82 MAINTENANCE Periodic Maintenance Interval Table 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). ...

84 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 80 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 k...

85 MAINTENANCE Lubrication Chaincase Oil Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning on page 79. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube. See page 122 for the part num...

87 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow. Fuel Pump All fuel pump service must be performed by an authorized POLARIS dealer. Do not at...

88 MAINTENANCE Spark Plugs Spark Plug Recommendations A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to the specifications section for the specific spark plu...

89 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. CAUTIO...

90 MAINTENANCE Oil Lines Inspect oil line condition every 1000 miles (1600 km) as outlined in the maintenance charts beginning on page 79. Oil Filter Please see your dealer for replacement of the in-line oil filter every 2000 miles (3200 km) as outlined in the maintenance charts beginning on page 79...

91 MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or operated at extremely low temperatures, greater pro...

92 MAINTENANCE Cooling System Engine Overheating The over-temperature indicator on the instrument cluster will illuminate when the engine is overheating. The indicator will flash when engine temperature reaches critical levels. Illuminated Indicator Take action to cool the engine: • Drive in loose s...

93 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...

94 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. Nev...

95 MAINTENANCE Drive Chain Tension (RMK/ASSAULT RMK) 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 leve...

96 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 59. 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 ...

97 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 PO...

98 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...

99 MAINTENANCE Lights When servicing a halogen lamp, avoid 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 foa...

100 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. WARNING! If you become aware of higher than normal clutch engagement or an unusual vibration or shift patt...

101 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. Always carry a spare drive ...

102 MAINTENANCE Clutch System 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). Drive Belt Adjust...

103 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 ...

104 MAINTENANCE Clutch System Drive Belt Installation 1. With the L-wrench inserted into the threaded hole and the sheaves in the open position, install the drive belt. TIP: 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 b...

105 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 ...

106 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 ...

107 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 106. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. 8. Tighten or...

108 MAINTENANCE Track 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. Start the engine a...

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

110 MAINTENANCE Steering System 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. 1. Place the handlebars in a straight-ahead ...

111 MAINTENANCE Steering System Ski Skags WARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the origi...

112 MAINTENANCE Steering System 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. Failure to do so ...

113 MAINTENANCE Battery (if equipped) WARNING! Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative...

114 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed...

115 MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully. 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 u...

116 MAINTENANCE Fall Tune-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. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Be sure the ...

117 MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Maintenance Table beginning on page 80. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch sha...

118 SPECIFICATIONS 600 RMK / 600 PRO RMK Capacities and Dimensions Body Style PRO-RIDE Rider Capacity 1 Coolant Capacity 6 qts. (5.7 l) (RMK 144)6.3 qts. (6.0 l) (RMK 155)5.3 qts. (5.0 l) (PRO RMK 155) Chaincase Oil Capacity 9 oz. (266.2 ml) (600 RMK)N/A (600 PRO RMK) Fuel Tank Capacity 11.5 gal. (4...

119 SPECIFICATIONS 600 RMK 144 / 600 RMK 155 600 PRO RMK 155 Clutching Chart ALTITUDE Meters (Feet) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-450 (0-1500) 10-64 (1321585) Black/Green (7042083) L...

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

123 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Erratic engine RPM during acceleration or load variations Drive clutch binding • SEE YOUR DEALER. Driven clutch malfunction • SEE YOUR DEALER. Engine doesn't turn Seized engine • SEE YOUR DEALER. Seizure is a result of poor l...

124 TROUBLESHOOTING Drive System Troubleshooting Problem Probable Cause Solution Machine fails to move Clutch jammed • Check for twisted belt or broken spring. SEE YOUR DEALER. Track jammed • Foreign object may be caught or the rail slide melted to the track clips due to lack of lubrication. • Track...

125 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 wea...

126 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bottoms too easily • Refer to the suspension adjustment and set-up information beginning on page 50. • Revalve rear track shock (see your dealer). Rides too stiff in rear • Refer to the suspension adjustment and set-up i...

127 WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance 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. Your dealer receives frequent updates on...

128 WARRANTY Limited Warranty POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED WARRANTY on all components of the POLARIS snowmobile against defects in material or workmanship. Warranty period will vary regionally. This warranty covers the parts and labor charges for...

130 WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a POLARIS Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the con...

131 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for expor...

132 WARRANTY 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 ...

135 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. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km)...

137 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . 30Air Pollution . . . . . . . . . . . . . . . . . . . . 6Avalanches . . . . . . . . . . . . . . . . . . . . 15 B Battery . . . . . . . . . . . . . . . . . . 113-115 Charging . . . . . . . . . . . . . . . 114-115Installation . . . . . . ...

5 INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. Some of the illustrations and photos used in this manual are general representations. Your model may differ. Follow th...

6 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 veg...

7 INTRODUCTION Vehicle Identification Numbers Record your snowmobile’s identification numbers and key number in the spaces provided. 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 lo...

8 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 symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual...

9 SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 70 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full attention. ...

10 SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. WARNING Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay...

11 SAFETY Operator Safety Survival Preparation For your safety, always ride in a group of other snowmobilers. Always tell someone where you’re going and how long you expect to be gone. If it isn’t possible to ride with others, and you must travel into remote areas, always carry survival equipment th...

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. Rider Capacity Your Polari...

13 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. Guy wi...

14 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: S Take an avalanche class S Travel with experienced people S Travel on designated trails S Make sure each person is equipped with a shovel, probe and avalanche be...

15 SAFETY Operator Safety Ice and Snow Build-up WARNING Ice and snow build-up may interfere with the steering of your machine, 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 ...

16 SAFETY Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly ter...

17 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. Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do not operat...

18 SAFETY Operator Safety Inadequate Snow Conditions WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models...

19 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. E...

20 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART ( ° F) Wind Speed in MPH Actual Thermometer Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Eq...

21 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals and other warnings on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always r...

+ 22 SAFETY Safety Decals and Locations Track Warning WarmingStay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. “No Passenger” Warning WarmingThis vehicle is designed for operator only.“NO PASSENGER” +

23 SAFETY Safety Decals and Locations Reverse Warning Reverse operation, even at low speeds, may cause loss of control resulting in serious injury or death. To avoid loss of control, always: S Look behind before and while backing. S Avoid sharp turns. S Shift to or from reverse only when stopped. S ...

24 SAFETY Safety Decals and Locations Operation Warning S To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If the manual is miss- ing, contact a Polaris dealer for a replacement. S This vehicle is capable of high speeds. Buried objects or un...

10 4 3 2 1 14 6 12 11 13 15 9 7 5 7 8 25 FEATURES 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Side Shield 6. Seat 7. Storage Compartment 8. Taillights 9. Rear Bumper 10. Snow Flap 11. Suspension 12. Track 13. Nosepan 14. Front Bumper 15. Ski 1. Fuel Filler Cap 2. Rider Select t 3. Ignition Sw...

26 FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system allows you to adjust the handlebar position to fit your style of riding. Choosing the Best RIDER SELECT t Position Position Riding Style 123 Relaxed Trail Riding Rider weight is slightly behind the center...

27 FEATURES RIDER SELECT Adjustable Steering System WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system. 1. Stop the snowmobile.2. Pr...

29 FEATURES Detonation Elimination Technology (D.E.T.) The DET system prevents damage to the engine from detonation while developing the maximum power of the engine safely. A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing. This can result...

30 FEATURES Instrumentation MFD Component Identification Item 1 Analog Gauge 2 Digital Gauge 3 DET Indicator 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interva...

31 FEATURES Instrumentation MFD Settings With the engine running, use the MFD Control Switch (1) to set the MFD display to your preference. The rocker switch has a MODE button (2) and a SET button (3). Standard vs. Metric The MFD will display either standard or metric units of measurement. While vie...

32 FEATURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program will remain in the display until another is selected. NOTE: The analog will always display either MPH or engine RPM (whichever setting...

33 FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting 1. While in the CLOCK display, press and hold the SET button for five seconds. 2. When the hour starts flashing press the SET switch once to advance one hour, or press and hold the SET button to advance the ho...

34 FEATURES Instrumentation MFD Digital Display Programs Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. NOTE: Press and hold the MODE switch for ten seconds to switch between standard and...

35 FEATURES Instrumentation MFD Digital Display Programs History Program The History Program automatically displays electrical system voltage level and fuel level.While in the History mode, press the SET button to view maximum vehicle speed, maximum engine rpm or the current service interval setting...

36 FEATURES Instrumentation MFD Digital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due. “SErVCE” will fl...

37 FEATURES Instrumentation MFD Battery Replacement If the clock function of the MFD isn’t working properly, replace the battery. Replacement batteries are available from your dealer.1. Remove the plenum from the underside of the hood. 2. Locate the black battery compartment (1). It has a red wire a...

38 FEATURES Instrumentation Gauge Cleaning 1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, soft cloth. 2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution. Do not remove the electrical connectors or ...

1 2 4 3 39 THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments.Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and tra...

40 THE PERFECT FIT IQ Front Suspension Adjustments Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris dealer for assistance before attempting to adjust preload.Increasing the spring preload too much may adversely affec...

41 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect 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 a...

42 THE PERFECT FIT Rear Suspension Adjustments Rear Suspension 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 suspen...

43 THE PERFECT FIT Rear Suspension Adjustments Rear Torsion Spring Tension To adjust rear torsion spring tension, 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 foll...

L 44 THE PERFECT FIT Rear Suspension Adjustments Rear Shocks Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock.Locate the adjustment screw ( ...

L 45 THE PERFECT FIT Rear Suspension Adjustments Rear Shocks ARVIN Rapid Adjust Shock The ARVIN Rapid Adjust shock is available as an option on some models. Turn the Rapid Adjust knob ( L ) on the shock reservoir to make adjustments to the compression damping.Positions are labeled on the shock. When...

46 THE PERFECT FIT Handlebar Adjustments Handlebar Position Use the RIDER SELECT feature to adjust handlebar position. See page 26. Handlebar Angle Follow these steps to adjust handlebar angle at the handlebar block.1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster bloc...

47 THE PERFECT FIT 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: S Non-compliance with government/industry requ...

48 THE PERFECT FIT Traction Products (SwitchBack only) Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products.Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure ...

49 THE PERFECT FIT Traction Products (SwitchBack only) n 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 maint...

51 PRE-RIDE INSPECTIONS Before Starting the Engine WARNING Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and re...

52 PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure...

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 1/2 ″ (1.3 cm). A smaller distance indicates low brake fluid level o...

4 3 1 2 54 PRE-RIDE INSPECTIONS Before Starting the Engine n Park Brake Lever Lock Use the park brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less.1. Brake Lever 2. Park Brake Lever Lock 3. Master Cylinder...

55 PRE-RIDE INSPECTIONS Before Starting the Engine n Track WARNING Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle. Use of tr...

56 PRE-RIDE INSPECTIONS Start the Engine and Check n Engine Stop Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. n Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF . n Tether...

CHOKE TOGGLE POSITIONS OFF HALF ON FULL ON 57 OPERATION Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Startin...

58 OPERATION Starting the Engine Starting a Warm Engine 1. Turn the key to the ON position. 2. Pull the engine stop switch up to the RUN position. 3. Grasp the recoil rope handle and pull slowly until the recoil engages; then pull abruptly. NOTE: If the engine does not start on the first pull, sligh...

59 OPERATION Engine Break-In Oil Injection System Always fill the oil tank when refueling. See page 63. CAUTION Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn’t go down, contact your dealer immediat...

61 OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel outdoors or in a well-ventilated area. S Always turn off the engine before refueling. S Do not overfill the tank. Do not fill t...

62 OPERATION Fuel For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use fuel lower than 87 octane. CAUTION Operating with obstructed fuel systems will result in ...

63 OPERATION Oil n Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low. Visually check the oil level in the bottle. Add oil before further operation of the snowmobile. See page 59 for oil recommendations. n Low Oil Level Maintaining the proper oil leve...

64 OPERATION n Engine Stop Switch Push down on the engine stop switch ( L ) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is r...

66 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 64 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All...

67 OPERATION Emergency Starting If the recoil starter system fails, an emergency start strap is provided in the tool kit.1. Open the hood.2. Remove the left side panel.3. Using the belt removal tool, follow the directions on the air box to relieve belt tension. 4. Starting at one of the tower struts...

68 OPERATION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine RPM is below 4000. 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 transmission if shifting is ...

69 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 ″ (10 cm) off the ground.Remove the key and cover the machine. Towing WARNING Objects towed with a rope...

70 MAINTENANCE Polaris Recommended Maintenance Program To 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 120.The recommende...

71 MAINTENANCE Periodic Maintenance Interval Table 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 d...

74 MAINTENANCE Lubrication Front Suspension The front suspension and steering components do not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-sea...

+ + 75 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lig...

1 2 3 76 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 71. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). C...

4 77 MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4) and drain the oil into a drain pan. Allow the oil to drain completely 3. Install a new sealing washer on the drain plug. NOTE: The sealing surfaces on the drain plug and the...

78 MAINTENANCE General Maintenance Spark Plugs A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization.Change the spark plugs every 2000-2500 miles (3200-4000 km). CAUTION U...

2 79 MAINTENANCE General Maintenance Spark Plugs 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. WARNIN...

+ 80 MAINTENANCE General Maintenance Intake Filters The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. CAUTION Operating the snowmobile with the intake filters rem...

81 MAINTENANCE General Maintenance Oil Filter/Oil Lines Inspect oil line condition at 1000 miles (1600 km). The oil filter should be changed annually or every 1000 miles (1600 km). The oil filter is located on the left side of the bulkhead behind the drive clutch.Have your dealer perform the filter ...

82 MAINTENANCE General Maintenance Carburetor The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It’s your dealer’s responsibility to make sure the correct main jet is installed. CAUTION Op...

83 MAINTENANCE General Maintenance Carburetor Water/Sediment Trap Most Polaris snowmobiles contain patented carburetor bowl water/sediment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for ...

84 MAINTENANCE General Maintenance Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing. Contact your dealer if greater protection is required.Use Premium 60/40 anti-freeze coolant, which is already pr...

85 MAINTENANCE General Maintenance Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine coolant temperature becomes too hot for safe continued operation of the engine. If you must drive your machine after the high temperature indicator light has c...

86 MAINTENANCE General Maintenance Bleeding the Cooling System Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part. WARNING Steam and hot liquids will cause serious burns to your s...

1 2 87 MAINTENANCE General Maintenance Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension:1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the ...

88 MAINTENANCE General Maintenance n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 53.Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 ″ ). A kit is available for replacing brak...

89 MAINTENANCE General Maintenance Brake Fluid WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake...

90 MAINTENANCE General Maintenance 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 ...

2 1 3 91 MAINTENANCE General Maintenance Removing Halogen Bulbs NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel. 1. Remove the plenum...

92 MAINTENANCE General Maintenance Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. WARNING If you become aware of higher than normal clutch engagement or an unusual vibra...

+ 93 MAINTENANCE General Maintenance n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions ...

94 MAINTENANCE General Maintenance Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them...

A B .010 ″ -.030 ″ (.25-.75mm) 95 MAINTENANCE General Maintenance n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position.Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1...

2 1 3 6 4 5 96 MAINTENANCE General Maintenance Tool Kit A tool kit is included with each machine for emergency and routine maintenance. Always keep the tool kit with the snowmobile.1. Emergency Start Strap2. L-Wrench3. Spark Plug Wrench/Screwdriver 4. Scissor Stop Wrench5. Combination Wrench6. Open ...

L 97 MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods are a serious safety hazard. They can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 1. Using a hois...

98 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...

99 MAINTENANCE Track Maintenance Track Tension I f the track needs adjustment: 5. Loosen the rear idler shaft bolt (D). 6. Loosen the locknuts (A).7. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track. 8. Repeat the measurement on the...

+ 100 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 machine with the track off the ground. 2. Start the engine a...

+ + + + 101 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary.

X Y 10 ″ 10 ″ 102 MAINTENANCE Steering System 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 straig...

+ 103 MAINTENANCE Steering System n Ski Skags WARNING Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death.See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the ori...

+ 7/16 ″ (1.1 cm) 104 MAINTENANCE Steering System n Rail Slide Measure slide thickness at several points along the rail. Have your dealer replace the slide when it’s worn down to the top of the wear groove ( + ). Do not operate the snowmobile if slide thickness measures less than 7/16 ″ (1.1 cm). Su...

105 MAINTENANCE Suspension MaintenanceExtended 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 108 for the part numbers of Polaris products. Cleaning and Preservation Prope...

106 MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch co...

107 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts. Track and Suspension Moderate track tension should be maintained dur...

108 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Go...

109 TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine operating RPM during Drive clutch binding S SEE YOUR DEALER. RPM during acceleration or ...

112 TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension bottoms too easily - Verify sag dimension (see page 42). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. - Increase shock compressio...

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

114 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance 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. Your dealer receives frequent updates on...

115 WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective ...

117 WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre- Delivery Inspection, perform all applicable service bulletins and have the co...

118 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is...

119 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for e...

120 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. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km)...

122 INDEX A Accessories 47 . . . . . . . . . . . . . . . . . . . . Adjustable Headlights 28 . . . . . . . . . . . . Avalanches 14 . . . . . . . . . . . . . . . . . . . . B Bearings 106 . . . . . . . . . . . . . . . . . . . . . Before Starting the Engine 51-55 . . . . . . Belt Troubleshooting 113 . ....