Polaris 600 Fusion - User Manual

5 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. We encourage governments to adopt rigorous safety training pro- grams that encourage protection of our environment, including wildlife and vegetation. Snowmobile clubs and other o...

6 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 , on your vehicle or in this manu...

7 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 84 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. DO NOT dr...

8 SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Stay Clear of Engine Never attempt adjustments with the engine running. Turn off the igni- tion, raise the hood, make the adjustment, secure shields and...

9 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmobiles, but under many conditions, the proper position is to be seated with both feet on the running boards ...

10 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...

11 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...

12 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...

13 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...

14 SAFETY Operator Safety Ice and Snow Build-up Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage. NOTE: I...

15 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the machine 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 machine and keep it from rolling freely downhill...

16 SAFETY Operator Safety Driving in Hilly Terrain Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you must cross the face of a slope, keep your weight on the uphill side of the machine to maintain proper balance and avoid po...

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 Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your machine. Driving in too lit- tle snow will result in excessive...

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 machine 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 tem- peratures become dangerous for riding. WIND CHILL CHART ( _ F) WIND CHILL CHART ( _ C) Estimated Wind Speed in MPH Actual Thermometer Reading ( _ F) 50 40 30 20 10 0 -10 -20 -...

21 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protec- tion. Read and follow the instructions of the decals and other warnings on the snowmobile carefully. If any of the decals depicted in this man- ual differ from the decals on your snowmobile, alwa...

22 SAFETY Safety Decals and Locations Track Warning The track warning decal is on the rear of the tunnel: 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. "No Passenger" Warning The "NO PASSENGER"...

23 SAFETY Safety Decals and Locations Reverse Warning The reverse warning decal is located on the console below the wind- shield: WARNINGReverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always: • Look behind before and w...

25 FEATURES 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Snow Flap 7. Suspension 8. Track 9. Storage Compartment 10. Rear Bumper 11. Taillights 12. Nosepan 13. Front Bumper 14. Skis 5 8 2 3 4 7 6 14 12 13 1 9 9 10 11

27 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. Setting Position Riding Style Comfort 1, 2 Pull the system rearward to one of the first two positions for all-day trail riding comf...

28 FEATURES RIDER SELECT Adjustable Steering System 1. Stop the snowmobile.2. Press the release button and move the handlebar forward or rearward to the desired position. WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious in...

29 FEATURES Fuel Valve The fuel valve is located under the hood. Turn the fuel valve off when- ever the snowmobile is stored or parked. 1. Turn the valve clockwise to turn off the fuel supply. 2. Turn the valve counter-clock- wise to turn on the fuel supply. Seat Storage Compartment Open or close th...

30 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 sen- sor monitors the engine and responds to detonation by automatically reducing the engine timing. This can resu...

31 FEATURES Detonation Elimination Technology (D.E.T.) DET Troubleshooting Use this chart to determine causes and solutions for detonation. If none of these conditions exists and the sensor remains activated, see your Polaris dealer for diagnosis. Sensor Fail-Safe The DET includes a sensor fail-safe...

32 FEATURES Instrumentation MFD Component Identification Digital Display 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 Item 1 RPM or Speed Altitude (if equipped) Service Interva...

33 FEATURES Instrumentation MFD Settings With the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch ( ✪ ) has a MODE but- ton (top) and a SET button (bottom). Standard vs. Metric The MFD will display either stan- dard or metric units of measureme...

34 FEATURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs: Per- formance, 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 setti...

35 FEATURES Instrumentation MFD Digital Display Programs Trip Settings Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled. 1. To reset a trip odometer to zero, enter the Trip 1 or Trip 2 display. 2. Press and hold the SET button for two seconds. Trip F a...

36 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...

37 FEATURES Instrumentation MFD Digital Display Programs Engine Program The Engine Program automatically displays the engine coolant tempera- ture, engine hours, electrical system voltage level and fuel level. On machines equipped with altimeter sensor and ambient air temperature sensors, altitude a...

39 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 set- t...

40 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"...

41 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 under- side of the hood. 2. Locate the black battery compart- ment. It has a red wire ...

43 THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for about 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 trail conditions. ...

44 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 attempt- ing to adjust preload. Increasing the spring preload too much may adversely af...

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 design...

46 THE PERFECT FIT Rear Suspension Adjustments Suspension Performance Tips • Rider weight usually determines the position at which the spring pre- load should be set. However, this may vary with riding style. With a little experimentation, each rider can find a preferred setup. These adjustments are...

47 THE PERFECT FIT IQ Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the IQ rear suspension tor- sion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspensi...

48 THE PERFECT FIT IQ Rear Suspension Adjustments Torsion Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will ...

49 THE PERFECT FIT IQ Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of sus- pension coupling, these torque arms could move independently of each other. Rear suspens...

50 THE PERFECT FIT IQ Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen- dent movement between the rear torque and the front...

51 THE PERFECT FIT IQ Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. To decrease weight trans...

52 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments The M-10 suspension has been designed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. (11 kg) or more might require appropriate changes in settings. The following information has been compiled to assist you in tuning y...

54 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings FRA Position The FRA setting is the primary rear suspension adjustment. It will have the MOST effect on the rear suspension performance. To adjust the FRA: 1. Refer to the initial set-up reference chart (loc...

55 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings Rear Spring Preload If FRA position alone does not allow the setup of the proper amount of sag, the center retainer of the rear track shock can be replaced with optional retainers to adjust the preload and c...

56 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter strap and front arm ...

57 THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Ski Pressure 4. There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole (1) increases ski pressure while the upper hole (2) decreases ski pressure. NOTE: By design, the BIASED COUPLE design of...

58 THE PERFECT FIT Handlebar Adjustments Handlebar Position Use the RIDER SELECT feature to adjust handlebar position. See page 27. Handlebar Angle Follow these steps to adjust handlebar angle at the handle- bar block. 1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster b...

59 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 requ...

60 THE PERFECT FIT Traction Products 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 warran- ties are void if track damage or failure results from im...

61 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...

62 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 ref- erenced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspection items. Item See P...

63 PRE-RIDE INSPECTIONS Before Starting the Engine Read and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable snowmobiling experience. n Throttle Lever The throttle and brake are the primary controls of your snowmo...

64 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...

65 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 Lever2. Park Brake Lever Lock3. Master Cylinder Reser- v...

66 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the stee...

67 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...

68 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 ...

69 OPERATION Starting the Engine Starting a Cold Engine (Manual Start) Do not depress the throttle until the engine starts. 1. Turn the fuel valve on. See page 29. 2. Turn the key to the ON position. 3. Pull the engine stop switch up to the RUN position. 4. Flip the choke toggle to FULL ON. 5. Grasp...

70 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. If the engine does not start on the first pull, slightly depr...

71 OPERATION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 75. Oil Recommendations This snowmobile is equipped with a variable exhaust system (VES). Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends th...

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

74 OPERATION Fuel For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor- mance will be lost and fuel economy will decrease. Do not use fuel lower than 87 octane. Fuel Level The fuel symbol and the last fuel bar on the MFD ...

75 OPERATION Oil n Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 71 for oil recommendations. n Low Oil Level Maintaining the proper oil level will...

76 OPERATION Carburetion Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance. A le...

77 OPERATION Carburetion Jetting Guidelines Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. The carbu...

80 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 78 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All...

81 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 strut...

82 OPERATION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine RPM is below 4000. 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 s...

83 OPERATION Daily Storage At the end of each ride, park the snowmo- bile on a level surface and support 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 machine. Towing If the snowmobile becomes inop...

84 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 138. The recom...

85 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...

88 MAINTENANCE Lubrication Front Suspension The front suspension and steering components do not require lubrica- tion. 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-s...

89 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 lightly...

90 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 84. 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). Change ...

91 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 o...

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

93 MAINTENANCE General Maintenance Spark Plug Condition 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....

94 MAINTENANCE General Maintenance Spark Plug Removal and Replacement 1. Remove the spark plug cap.2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plug installation. 4. Torque to 18-22 ft. lbs. (24-30 Nm).5....

95 MAINTENANCE General 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...

96 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. Carburetor...

97 MAINTENANCE General Maintenance Carburetor Water/Sediment Trap Most Polaris snowmobiles contain patented carburetor bowl water/sedi- ment 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 fo...

98 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 p...

99 MAINTENANCE General Maintenance Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine cool- ant temperature becomes too hot for safe continued operation of the engine. If you must drive your machine after the high temperature indi- cator light h...

100 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. Perform the bleeding procedure when the engine is cold. 1. Remo...

101 MAINTENANCE General Maintenance Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing re...

102 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 counter- clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the ...

103 MAINTENANCE General Maintenance n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 64. 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 ...

104 MAINTENANCE General Maintenance 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...

105 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. During the bleeding procedure, keep the brake handle as level as possi- ble. The reservoir must be in this...

106 MAINTENANCE General Maintenance 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. Headlight Bulb Removal 1. Remove the plenum cov...

107 MAINTENANCE General Maintenance Taillight/Brakelight Replacement 1. Open the rear storage compart- ment. 2. Reach into the compartment and locate the socket assembly above the door opening. 3. Turn the socket counterclockwise 1/4 turn. 4. Carefully pull the socket assembly away from the tailligh...

108 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. Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum p...

109 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 e...

110 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 identifica- tion numbers so that you can read t...

111 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 (1) on the belt and apply downward pres- sure while measuring at point 2. This measurement should be 1 1/4 I (3.2 cm). Drive Belt A...

112 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. Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained se...

113 MAINTENANCE Track Maintenance Track Inspection 1. Using a hoist, safely lift and support the rear of the snow- mobile off the ground. 2. Rotate the track by hand to check for damage. 3. Carefully examine the track along the entire length of each rod ( ✪ ). Bend the track to check for breakage. 4...

114 MAINTENANCE Track Maintenance Track Tension Track adjustment is critical for proper handling. Always maintain cor- rect tension and alignment. NOTE: Tension adjustments should be made only after the track is warmed up and limber. 1. Turn the engine off.2. Lift the rear of the machine and safely ...

115 MAINTENANCE Track Maintenance Track Tension 4. 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 114. If the track needs adjustment: 5. Loosen the rear idler shaft bolt.6. Loosen the locknuts. 7. Tighten or ...

116 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 and...

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

118 MAINTENANCE Steering System Ski Alignment With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt. The measurement between the skis at point X should be 1/8 I to 1/4 I ...

119 MAINTENANCE Steering System n Ski Skags Some models have one skag, others may have dual skags. Check skags before each use of the snowmobile to ensure positive steering character- istics. Skags must be replaced when worn to half their original diameter. NOTE: Carbide skags must be replaced if an...

120 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)....

121 MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 124 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts wit...

122 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...

123 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...

124 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...

125 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...

128 TROUBLESHOOTING IQ Suspension Troubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper static sag (see page 47). • Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear track shock (see your dealer). Ride...

129 TROUBLESHOOTING M-10 Suspension Troubleshooting Problem Solution Rear suspension bot- toms too easily • Increase FRA position (see setup decal under hood for ini- tial position. • Install appropriate optional center retainer on rear track shock (see page 55). • Increase front track shock coil sp...

130 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 machine in extremely cold weathe...

131 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, ser- vice or warranty. Your dealer receives frequent update...

132 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...

133 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 ...

135 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...

136 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 ...

137 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 ex...

138 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...

140 INDEX A Accessories . . . . . . . . . . . . . . . . . . 59 Adjustable Headlights . . . . . . . . . . 29Adjustable Steering System . . . . 27-28Air Pollution . . . . . . . . . . . . . . . . . . 5 Avalanches. . . . . . . . . . . . . . . . . . . 13 B Bearings . . . . . . . . . . . . . . . . . . . ....