Polaris 800 INDY - Manual

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

6 INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and veg...

7 INTRODUCTION Vehicle Identification Numbers Record your snowmobile’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if both keys are lo...

8 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal inju...

10 SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Do not stand on the plastic flap. WARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding,...

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

12 SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Survival Preparation For y...

13 SAFETY Operator Safety Rider Capacity This snowmobile is designed for a single rider only. Never carry a passenger on this snowmobile. Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in incleme...

14 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wi...

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

16 SAFETY Operator Safety Ice and Snow Build-up WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow ...

17 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the snowmobile and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the snowmobile and keep it from rolling freely do...

18 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. NOTICE: Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do no...

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

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

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

22 SAFETY Safety Labels and Locations No Passenger Warning/Fuel Recommendation Label WARNING This vehicle is designed for operator only. NO PASSENGER FUEL RECOMMENDED 91+ OCTANCE WITHOUT ETHANOL For maximum performance see decal on left hand side panel for proper gauge setting. 7178713 Reverse Warni...

23 SAFETY Safety Labels and Locations Track Warning WARNING Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back can result in severe injury or death. 7172519 Hot Surface Warning WARNING Hot Surface Do Not Touch Burns may result. Entire top of tunnel may...

26 FEATURES 9 14 5 6 7 13 12 2 1 3 4 11 10 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. Windshield (accessory) 7. Handlebar 8. Fuel Filler Cap 9. Operator Seat 10. Taillight11. Rear Bumper12. Snow Flap13. Suspension14. Track15. Side Panel16. Side Panel Strap17. Side Panel Fasteners 16 ...

28 FEATURES Adjustable Headlights Move the headlight adjuster to the left to adjust the headlight beam upward. Move the adjuster to the right to adjust the beam downward. Cargo Storage The maximum weight capacity for the cargo area is 15 lbs. (7 kg). Always secure cargo before operating. Do not exce...

29 FEATURES Fuel Type Selection Whenever using ethanol, MTBE or other forms of oxygenated gasolines, the fuel type designation setting must be changed to “ETH” in the gauge. When using the recommended 91 non-ethanol gasoline, always select the “91-NON” setting. Whenever in doubt of your fuel purchas...

30 FEATURES Detonation Elimination Technology (DET) The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate and you may notice decreased engin...

31 FEATURES Detonation Elimination Technology (DET) The most likely causes of severe detonation are outlined in the troubleshooting table below. DET Troubleshooting Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol/non-ethanol fuel type setting Ver...

33 FEATURES Engine Overheat Indicators The over-temperature indicator in the instrument cluster will illuminate when the engine is overheating. Take action to cool the engine. See Engine-Cooling Actions below. The indicator will flash when engine temperature reaches critical levels. Stop the engine ...

34 FEATURES Instrument Cluster (Digital/Analog) The instrument cluster contains the speedometer, indicator lamps, MODE button and rider information center. NOTICE: Certain products will damage the lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Immediately clean ...

35 FEATURES Instrument Cluster (Digital/Analog) Indicator Lamps Lamp Indicates Condition Vehicle Speed When standard mode is selected, speed displays in miles per hour. When metric mode is selected, speed displays in kilometers per hour. Reverse This indicator flashes when the transmission is in rev...

36 FEATURES Instrument Cluster (Digital/Analog) Rider Information Center The information center can be controlled by either the MODE button on the instrument cluster or by the MODE/SET switch on the left handlebar. Setting changes must be made with the engine running or with the vehicle powered by a...

37 FEATURES Instrument Cluster (Digital/Analog) Rider Information Center Display Units (Standard/Metric) The display can be changed to display either standard or metric units of measurement. While in the engine temperature display, press and hold the MODE button to change units. Odometer Mode The od...

38 FEATURES Instrument Cluster (Digital/Analog) Rider Information Center Security System (Ignition Lock System) This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer. If you have this feature activated, you can lock the ignition to pre...

40 FEATURES Instrument Cluster (Digital/Analog) Rider Information Center Security System (Ignition Lock System) Locking the System With Your Personal Security Code 1. Start the engine and lock the parking brake. 2. Press and hold the MODE and SET buttons for 3 seconds, then release. SECURE OFF shoul...

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

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

43 FEATURES Instrument Cluster (Digital/Analog) Rider Information Center Diagnostic Display Mode The diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. If a system error occurs, the check engine indicator will illuminate. Do not stop the...

45 FEATURES Instrument Cluster (MFD) Indicator Lights 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 57 for diagnostic code definitions. Over-Temperatur...

47 FEATURES Instrument Cluster (MFD) Rider Information Center 1. Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. To change the display, see page 48. 2. Speed Display - ...

48 FEATURES Instrument Cluster (MFD) 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...

49 FEATURES Instrument Cluster (MFD) 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...

50 FEATURES Instrument Cluster (MFD) 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 M...

51 FEATURES Instrument Cluster (MFD) Rider Information Center Security System (Ignition Lock System) This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer. If you have this feature activated, you can lock the ignition to prevent unauth...

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

56 FEATURES Instrument Cluster (MFD) 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 an...

57 FEATURES Instrument Cluster (Digital/Analog and MFD) 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 ...

59 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 experience for most riders. If all rear shock spring adjustments have been exhausted...

60 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 pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same...

61 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs ...

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

63 THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, 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 req...

64 THE PERFECT FIT 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 suspension coupling, these torque arms could move independently of each other. Rear suspension c...

66 THE PERFECT FIT 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 transfer...

67 THE PERFECT FIT Traction Products Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle s...

68 THE PERFECT FIT Handlebar Component Fastener Torques Component Torque Do not over-tighten IMPORTANT: Moving a handlebar component without first loosening its screws/set screws may cut grooves into the handlebar, making it difficult to secure the component. Do not move a handlebar component withou...

69 THE PERFECT FIT Left Hand Control Alignment 1. Loosen the four control block mounting screws. CAUTION! Take care to avoid damaging hand warmer/brake switch wires when moving components. 2. Move the control block to the desired position. NOTE: If the control is loose and was inadvertently moved wi...

70 THE PERFECT FIT Handlebar Adjustments When adjusting handlebar position or angle, be sure the handlebar, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right. If necessary, adjust the left a...

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

73 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 ...

74 PRE-RIDE INSPECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2 inch (1.3 cm). A smaller distance indi-cates low brake fluid level...

75 PRE-RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary, such as when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder R...

76 PRE-RIDE INSPECTIONS Before Starting the Engine Steering System WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be...

77 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...

78 OPERATION Starting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the key to the ON position. 2. Pull the engine stop switch up to t...

79 OPERATION Break-In Period Engine Break-In Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine. Premix the first tank of fuel and fill the oil reservoir as outlined below. Oil added to the fuel and ...

80 OPERATION Break-In Period Engine Break-In Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Vary the throttle openings and vehicle speeds...

81 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...

82 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 ...

83 OPERATION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher, with no ethanol. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing mor...

84 OPERATION Oil Low Oil Level Always maintain the oil level between the “add” mark and the bottle neck. Do not fill the bottle neck. See page 79 for oil recommendations. 1. Immediately stop the engine if the low oil indicator light comes on. 2. Open the left side panel. 3. View the oil level in the...

85 OPERATION Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed fro...

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

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

88 OPERATION Electronic Reverse (PERC) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 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 runni...

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

90 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission control information (ECI) lab...

91 MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 140. The recommend...

92 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...

95 MAINTENANCE Hood and Side Panels The hood and side panels protect the operator from moving parts. Never operate a snowmobile with the side panels open or removed. Always ensure that the hood and side panels are installed and securely latched before starting the engine. To open a side panel, rotat...

96 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 92 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 k...

97 MAINTENANCE Lubrication Chaincase Oil Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning on page 91. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube. See page 126 for the part num...

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

99 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...

100 MAINTENANCE Intake Filters The intake filters on the left and right console limit snow ingestion into the intake system. When operating in loose powder snow, check the filters periodically to remove any accumulation of snow. Fuel Pump All fuel pump service must be performed by an authorized POLA...

101 MAINTENANCE Cooling System Coolant POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 126 for the part numbers of POLARIS products. To ensure that the coolant maintains its ability to protect the...

102 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 properl...

103 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. Ne...

104 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 74. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake...

105 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 P...

106 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 an...

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

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

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

110 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 ...

111 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 ...

112 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 ...

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

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

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

116 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 toe adjustment. See your POLARIS dealer. If the steering feels heavy, or if the snowmobi...

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

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

119 MAINTENANCE Battery (if equipped) Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sea...

120 MAINTENANCE Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your POLARIS dealer. His experienced and trained service technician will keep your snowmobile in peak operating condition. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Be sure the ...

121 MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Maintenance Table beginning on page 92. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch sha...

122 SPECIFICATIONS 600 INDY Capacities and Dimensions Body Style PRO-RIDE Rider Capacity 1 Coolant Capacity 5 qts. (4.7 l) Chaincase Oil Capacity 9 oz. (266.2 ml) Fuel Tank Capacity 11.5 gal. (43.5 l) Gearcase Oil Capacity N/A Oil Capacity 3.8 qts. (3.6 l) Height 48 in. (122 cm) Length 114 in. (289 ...

125 SPECIFICATIONS 800 INDY 800 INDY International Clutching Chart ALTITUDE Meters (Feet) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 10-66 (1321584) 120/310 Black (7043681) RED/BLK (...

126 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2878243 VES RACE 2-Cycle Engine Oil (qt./.95 l) 2878191 VES RACE 2-Cycle Engine Oil (gal./3.8 l) 2877882 VES 2-Cycle Oil (qt./.95 l) 2877953 VES 2-Cycle Engine Oil (2 qt./1.9 l) 2877883 VES 2-Cycle Engin...

127 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. Dri...

130 TROUBLESHOOTING Rear Suspension Troubleshooting Problem Solution Rear suspension bottoms too easily • Adjust torsion spring preload to achieve proper static sag (see page 62). • Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear track shock (see your dealer).• Rot...

131 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...

132 WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty. Your dealer receives frequent updates on...

133 WARRANTY Limited Warranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a 12 MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. This warranty covers parts and labor charges for repair or replacement of defecti...

134 WARRANTY Warranty Coverage and Exclusions Limitations of Warranties and Remedies This POLARIS Limited Warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God,...

136 WARRANTY How to Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YO...

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

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

142 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 28Air Pollution . . . . . . . . . . . . . . . . . . . 6Avalanches. . . . . . . . . . . . . . . . . . . . 15 B Battery . . . . . . . . . . . . . . . . . . 118-119 Charging . . . . . . . . . . . . . . . . 119Installation . . . . . . . . . ....