Polaris 600 RUSH - Manuals

6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. We encourage state and provincial governments across the snow- belt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and...

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 sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal in...

9 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 73 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.Ap...

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 pas- senger on this snowmobile. Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in incle...

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 beacon...

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 condi- tions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under various conditio...

20 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WINDCHILL CHART ( _ F) WINDCHILL CHART ( _ C) Wind Speed in MPH Actual Thermometer Reading ( _ F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -2...

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...

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

24 FEATURES 8 13 5 6 7 12 11 2 1 3 4 10 9 1. Nosepan2. Skis3. Front Bumper4. Hood5. Headlight6. Windshield (accessory)7. Handlebar 8. Operator Seat9. Taillight10. Rear Bumper11. Snow Flap12. Suspension13. Track14. Side Panel15. Side Panel Fasteners 15 14

26 FEATURES Storage Bag/Tool Kit A storage bag is located under the seat. The left portion of the bag is designed to store the tool kit. The tool kit includes tools and a foam tool holder. The right side of the bag can be used to stow other items. Adjustable Headlights Move the headlight adjuster to...

27 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. Depending on the level of detonation encountered, the check engine light could be solid, it could flicker or it ...

28 FEATURES Instrument Cluster The instrument cluster contains indicator lights and the rider infor- mation center. The information cen- ter can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the MODE/ SET switch on the left handlebar. NOTICE: Certain products wi...

29 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 36 for diagnostic code definitions. Over-Temperature Indicator ...

30 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine tempera- ture and diagnostic display m...

32 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 ch...

33 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 travel...

34 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 ...

35 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...

36 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...

38 THE PERFECT FIT Suspension Quick Set-Up Guide The suspension on your RUSH is incredibly easy to adjust to your weight and riding style. Just remember three simple steps:1. Set up rear shock spring preload for rider weight.2. Adjust the rear spring to tune vehicle balance (ski pressure and weight ...

39 THE PERFECT FIT Suspension Quick Set-Up Guide Step 2: Adjust the rear spring to tune vehicle balance. After the initial test ride, make adjustments to the rear shock spring to improve vehicle balance. Increasing preload will increase ski pressure and result in less weight transfer for flatter cor...

40 THE PERFECT FIT Suspension Quick Set-Up Guide Accessory rear shock springs are available for riders of different weights. A corresponding gauge is available for each spring type. The gauge provided with your snowmobile is calibrated for the stock 190 spring, which should be used by most riders. D...

41 THE PERFECT FIT Suspension Quick Set-Up Guide Polaris recommends that riders use this Quick Set-Up Guide to make any adjustments for rider weight and trail conditions. If additional tun- ing is needed after you have exhausted all possible adjustments to the rear shock spring and clicker, refer to...

42 THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS) Factory settings, combined with user adjustments to the rear shock spring, should be all that’s necessary to provide the best riding experi- ence for most riders. If all rear shock spring adjustments have been exhaust...

43 THE PERFECT FIT Front Suspension Adjustments IFS Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pres- sure. When adjusting, be sure the springs on both the left and right sides of the machine are at the sa...

44 THE PERFECT FIT Front Suspension Adjustments IFS Shock Compression Damping Make adjustments to the shock clickers to control bottoming. Make the adjustments in 1-to-2-click increments, then test ride. Repeat the adjust- ment until the desired result is achieved. TIP: Initially, heavier riders may...

45 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 sus- pension designs...

46 THE PERFECT FIT Rear Suspension Adjustments Front Track Shock Compression Damping Make adjustments to the shock clicker to control bottoming. Make the adjustments in 2-click incre- ments, then test ride. Repeat the adjustment until the desired result is achieved. TIP: Initially, heavier riders ma...

47 THE PERFECT FIT Rear Suspension Adjustments Rear Shock Spring Preload Settings Make adjustments to the rear shock spring to tune vehicle balance. Increasing preload will increase ski pressure and result in less weight transfer and flatter cornering and more precise steering response. Decreasing p...

48 THE PERFECT FIT Handlebar Adjustments Handlebar Position 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. Loosen the fo...

49 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:• Non-compliance with government/industry requi...

50 THE PERFECT FIT Traction Products Studs Use only Polaris traction products on your snowmobile. Track warran- ties are void if track damage or failure results from improper or exces- sive stud installation or the use of non-Polaris traction products.The longest stud length recommended for your fac...

51 THE PERFECT FIT Traction Products 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 maintain proper vehicle...

52 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspection items. Item See P...

53 PRE-RIDE INSPECTIONS Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the follow- ing items on a weekly basis or b...

54 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 ...

55 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 I (1.3 cm). A smaller distance indicates low brake fluid level o...

56 PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less.1. Brake Lever2. Parking Brake Lever Lock3. Master Cylind...

57 PRE-RIDE INSPECTIONS Before Starting the Engine n 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 ...

58 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...

59 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 th...

60 OPERATION Engine Break-In No single action on your part is as important to long, trouble-free snow- mobile life as proper break-in of a new or rebuilt engine. Premix the first tank of fuel with one pint of Polaris injection oil for each five gal- lons of fuel. This, in addition to the lubrication...

61 OPERATION Engine Break-In Oil Injection System Always check and fill the oil bottle when refueling. See page 65. 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 d...

62 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...

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

64 OPERATION Fuel Resistor This snowmobile is equipped with a feature that allows the engine control- ler to select the proper operating soft- ware based on the type of fuel being used. The proper fuel resistor must be installed to match the type of fuel you are using.The snowmobile comes from the f...

65 OPERATION n 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 61 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 th...

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

69 OPERATION Electronic Reverse (PERC t ) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or trans- mission if shifting is attempted when the engine is operating above idle speed.• Shift to or from re...

70 OPERATION Electronic Reverse (PERC t ) Engaging Reverse 1. Stop the snowmobile and leave the engine idling.2. Make sure the area behind your vehicle is clear.3. Push the yellow reverse button on the left-hand control for one sec- ond, then release. The engine will automatically reduce RPM and sta...

71 OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and sup- port it at the rear with an appropriate track stand. The track should be suspended approximately 4 I (10 cm) off the ground. Remove the key and cover the snowmobile. Towing For your safety, do not att...

72 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 con- trol information (ECI) l...

73 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log beginning on page 125.The recomm...

74 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...

78 MAINTENANCE Lubrication n Chaincase Oil Check and change the chaincase oil at the intervals outlined in the main- tenance charts beginning on page 73. Maintain the oil level at the top of the fill plug hole. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 110 for the part...

79 MAINTENANCE Lubrication n Chaincase Oil 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. 3. Clean off all metal shavings from the plug. Install a new sealing washer on the drain plug. TIP: Th...

80 MAINTENANCE Lubrication Rear Shock Body Threads Lubricate rear shock body threads seasonally. We recommend the use of Polaris Shock Thread Lubricant, a silicone spray lubricant. This lubri- cant is specifically designed for cold temperatures and high loads. Other silicone lubricants will not perf...

81 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...

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

83 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...

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

85 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 oper- ated at extremely low temperatures, greater p...

86 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 sn...

87 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...

88 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...

89 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. 3. Loosen...

90 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 55.Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approximately 1/16 I ). A kit is available for replacing brake pads. See y...

91 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 Pol...

92 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...

93 MAINTENANCE Lights When servicing a halogen lamp, avoid touching the lamp with bare fin- gers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol. Headlight Lamp Replacement 1. Peel back the f...

94 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 patte...

95 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition and tension of the drive belt. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshoot...

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

97 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 ...

98 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. 2. To ensure satisfactory belt life, install belts so they oper- ate in the same direction of rotation by positioning the identification numbers so that you can read them. If re...

99 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 r...

100 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 ...

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

102 MAINTENANCE Track Maintenance n Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail.1. Safely support the rear of the snowmobile with the track off the ground. 2. Start the engine ...

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

104 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 straight ahead posi...

105 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...

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

107 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. Matte Clear Coat Cleaning (if equipped) Matte finish products are prone to trapping...

108 MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Mainte- nance Table beginning on page 74. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch s...

109 MAINTENANCE Transporting the Snowmobile Whenever the snowmobile is transported:1. Be sure the fuel cap and oil cap are installed correctly.2. Tie the snowmobile to the transporting unit securely using suitable straps. 3. Remove the ignition key to prevent loss.

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

111 TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine oper- ating RPM during acceleration or load variations Drive clutch binding • SEE YOUR DEALER. Dr...

114 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bottoms too easily • Adjust rear shock spring (see pages 39 and 47).• Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear track shock (see your dealer). Rides too stiff in rear • Check for ...

115 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...

116 WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information con- tained in this manual. Contact your Polaris dealer for replacement parts, service or warranty. Your dealer receives frequent updates ...

117 WARRANTY Service and Warranty Information Polaris Anti-Theft System The Polaris anti-theft system (PATS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying th...

118 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 ...

120 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...

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

122 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...

125 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 k...

128 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 49 Air Pollution . . . . . . . . . . . . . . . . . . . 6 Avalanches. . . . . . . . . . . . . . . . . . . . 15 B Brake Lever Travel Inspection . . . . 55 Brakelight Replacement. . . . . . . . . . 93 Brakes . . . . . . . . . . . . . . . . ....

6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. We encourage state and provincial governments across the snow- belt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and...

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 sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal in...

9 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 73 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.Ap...

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 pas- senger on this snowmobile. Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in incle...

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 beacon...

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 condi- tions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under various conditio...

20 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WINDCHILL CHART ( _ F) WINDCHILL CHART ( _ C) Wind Speed in MPH Actual Thermometer Reading ( _ F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -2...

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...

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

24 FEATURES 8 13 5 6 7 12 11 2 1 3 4 10 9 1. Nosepan2. Skis3. Front Bumper4. Hood5. Headlight6. Windshield (accessory)7. Handlebar 8. Operator Seat9. Taillight10. Rear Bumper11. Snow Flap12. Suspension13. Track14. Side Panel15. Side Panel Fasteners 15 14

26 FEATURES Storage Bag/Tool Kit A storage bag is located under the seat. The left portion of the bag is designed to store the tool kit. The tool kit includes tools and a foam tool holder. The right side of the bag can be used to stow other items. Adjustable Headlights Move the headlight adjuster to...

27 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. Depending on the level of detonation encountered, the check engine light could be solid, it could flicker or it ...

28 FEATURES Instrument Cluster The instrument cluster contains indicator lights and the rider infor- mation center. The information cen- ter can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the MODE/ SET switch on the left handlebar. NOTICE: Certain products wi...

29 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 36 for diagnostic code definitions. Over-Temperature Indicator ...

30 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine tempera- ture and diagnostic display m...

32 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 ch...

33 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 travel...

34 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 ...

35 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...

36 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...

38 THE PERFECT FIT Suspension Quick Set-Up Guide The suspension on your RUSH is incredibly easy to adjust to your weight and riding style. Just remember three simple steps:1. Set up rear shock spring preload for rider weight.2. Adjust the rear spring to tune vehicle balance (ski pressure and weight ...

39 THE PERFECT FIT Suspension Quick Set-Up Guide Step 2: Adjust the rear spring to tune vehicle balance. After the initial test ride, make adjustments to the rear shock spring to improve vehicle balance. Increasing preload will increase ski pressure and result in less weight transfer for flatter cor...

40 THE PERFECT FIT Suspension Quick Set-Up Guide Accessory rear shock springs are available for riders of different weights. A corresponding gauge is available for each spring type. The gauge provided with your snowmobile is calibrated for the stock 190 spring, which should be used by most riders. D...

41 THE PERFECT FIT Suspension Quick Set-Up Guide Polaris recommends that riders use this Quick Set-Up Guide to make any adjustments for rider weight and trail conditions. If additional tun- ing is needed after you have exhausted all possible adjustments to the rear shock spring and clicker, refer to...

42 THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS) Factory settings, combined with user adjustments to the rear shock spring, should be all that’s necessary to provide the best riding experi- ence for most riders. If all rear shock spring adjustments have been exhaust...

43 THE PERFECT FIT Front Suspension Adjustments IFS Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pres- sure. When adjusting, be sure the springs on both the left and right sides of the machine are at the sa...

44 THE PERFECT FIT Front Suspension Adjustments IFS Shock Compression Damping Make adjustments to the shock clickers to control bottoming. Make the adjustments in 1-to-2-click increments, then test ride. Repeat the adjust- ment until the desired result is achieved. TIP: Initially, heavier riders may...

45 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 sus- pension designs...

46 THE PERFECT FIT Rear Suspension Adjustments Front Track Shock Compression Damping Make adjustments to the shock clicker to control bottoming. Make the adjustments in 2-click incre- ments, then test ride. Repeat the adjustment until the desired result is achieved. TIP: Initially, heavier riders ma...

47 THE PERFECT FIT Rear Suspension Adjustments Rear Shock Spring Preload Settings Make adjustments to the rear shock spring to tune vehicle balance. Increasing preload will increase ski pressure and result in less weight transfer and flatter cornering and more precise steering response. Decreasing p...

48 THE PERFECT FIT Handlebar Adjustments Handlebar Position 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. Loosen the fo...

49 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:• Non-compliance with government/industry requi...

50 THE PERFECT FIT Traction Products Studs Use only Polaris traction products on your snowmobile. Track warran- ties are void if track damage or failure results from improper or exces- sive stud installation or the use of non-Polaris traction products.The longest stud length recommended for your fac...

51 THE PERFECT FIT Traction Products 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 maintain proper vehicle...

52 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspection items. Item See P...

53 PRE-RIDE INSPECTIONS Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the follow- ing items on a weekly basis or b...

54 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 ...

55 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 I (1.3 cm). A smaller distance indicates low brake fluid level o...

56 PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less.1. Brake Lever2. Parking Brake Lever Lock3. Master Cylind...

57 PRE-RIDE INSPECTIONS Before Starting the Engine n 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 ...

58 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...

59 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 th...

60 OPERATION Engine Break-In No single action on your part is as important to long, trouble-free snow- mobile life as proper break-in of a new or rebuilt engine. Premix the first tank of fuel with one pint of Polaris injection oil for each five gal- lons of fuel. This, in addition to the lubrication...

61 OPERATION Engine Break-In Oil Injection System Always check and fill the oil bottle when refueling. See page 65. 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 d...

62 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...

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

64 OPERATION Fuel Resistor This snowmobile is equipped with a feature that allows the engine control- ler to select the proper operating soft- ware based on the type of fuel being used. The proper fuel resistor must be installed to match the type of fuel you are using.The snowmobile comes from the f...

65 OPERATION n 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 61 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 th...

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

69 OPERATION Electronic Reverse (PERC t ) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or trans- mission if shifting is attempted when the engine is operating above idle speed.• Shift to or from re...

70 OPERATION Electronic Reverse (PERC t ) Engaging Reverse 1. Stop the snowmobile and leave the engine idling.2. Make sure the area behind your vehicle is clear.3. Push the yellow reverse button on the left-hand control for one sec- ond, then release. The engine will automatically reduce RPM and sta...

71 OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and sup- port it at the rear with an appropriate track stand. The track should be suspended approximately 4 I (10 cm) off the ground. Remove the key and cover the snowmobile. Towing For your safety, do not att...

72 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 con- trol information (ECI) l...

73 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log beginning on page 125.The recomm...

74 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...

78 MAINTENANCE Lubrication n Chaincase Oil Check and change the chaincase oil at the intervals outlined in the main- tenance charts beginning on page 73. Maintain the oil level at the top of the fill plug hole. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 110 for the part...

79 MAINTENANCE Lubrication n Chaincase Oil 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. 3. Clean off all metal shavings from the plug. Install a new sealing washer on the drain plug. TIP: Th...

80 MAINTENANCE Lubrication Rear Shock Body Threads Lubricate rear shock body threads seasonally. We recommend the use of Polaris Shock Thread Lubricant, a silicone spray lubricant. This lubri- cant is specifically designed for cold temperatures and high loads. Other silicone lubricants will not perf...

81 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...

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

83 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...

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

85 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 oper- ated at extremely low temperatures, greater p...

86 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 sn...

87 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...

88 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...

89 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. 3. Loosen...

90 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 55.Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approximately 1/16 I ). A kit is available for replacing brake pads. See y...

91 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 Pol...

92 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...

93 MAINTENANCE Lights When servicing a halogen lamp, avoid touching the lamp with bare fin- gers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol. Headlight Lamp Replacement 1. Peel back the f...

94 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 patte...

95 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition and tension of the drive belt. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshoot...

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

97 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 ...

98 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. 2. To ensure satisfactory belt life, install belts so they oper- ate in the same direction of rotation by positioning the identification numbers so that you can read them. If re...

99 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 r...

100 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 ...

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

102 MAINTENANCE Track Maintenance n Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail.1. Safely support the rear of the snowmobile with the track off the ground. 2. Start the engine ...

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

104 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 straight ahead posi...

105 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...

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

107 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. Matte Clear Coat Cleaning (if equipped) Matte finish products are prone to trapping...

108 MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Mainte- nance Table beginning on page 74. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch s...

109 MAINTENANCE Transporting the Snowmobile Whenever the snowmobile is transported:1. Be sure the fuel cap and oil cap are installed correctly.2. Tie the snowmobile to the transporting unit securely using suitable straps. 3. Remove the ignition key to prevent loss.

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

111 TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine oper- ating RPM during acceleration or load variations Drive clutch binding • SEE YOUR DEALER. Dr...

114 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bottoms too easily • Adjust rear shock spring (see pages 39 and 47).• Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear track shock (see your dealer). Rides too stiff in rear • Check for ...

115 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...

116 WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information con- tained in this manual. Contact your Polaris dealer for replacement parts, service or warranty. Your dealer receives frequent updates ...

117 WARRANTY Service and Warranty Information Polaris Anti-Theft System The Polaris anti-theft system (PATS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying th...

118 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 ...

120 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...

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

122 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...

125 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 k...

128 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 49 Air Pollution . . . . . . . . . . . . . . . . . . . 6 Avalanches. . . . . . . . . . . . . . . . . . . . 15 B Brake Lever Travel Inspection . . . . 55 Brakelight Replacement. . . . . . . . . . 93 Brakes . . . . . . . . . . . . . . . . ....