Owners Manual
Page 27
... control the vehicle. Be seated and in insufficient time for you should have a proper balance of the throttle control assembly, to stop the engine. Check oil level when refueling. 23 If manual is designed for adult use extreme Warning caution when operating in unfamiliar terrain. • Excessive speed, especially at night or with a passenger (on approved models only) reduce speed and allow extra space to turn...
... control the vehicle. Be seated and in insufficient time for you should have a proper balance of the throttle control assembly, to stop the engine. Check oil level when refueling. 23 If manual is designed for adult use extreme Warning caution when operating in unfamiliar terrain. • Excessive speed, especially at night or with a passenger (on approved models only) reduce speed and allow extra space to turn...
Owners Manual
Page 29
Brake Lever MFD Gauge Ignition Switch Engine Stop Switch Throttle Control Recoil Starter Handle Parking Brake Lock Handlebar Grip Warmer Switch Thumbwarmer Switch Electronic Reverse Button Mode/Set Switch Headlight Dimmer Switch 7 8 9 10 12 11 25 FEATURES 2 3 1 4 5 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Brake Lever MFD Gauge Ignition Switch Engine Stop Switch Throttle Control Recoil Starter Handle Parking Brake Lock Handlebar Grip Warmer Switch Thumbwarmer Switch Electronic Reverse Button Mode/Set Switch Headlight Dimmer Switch 7 8 9 10 12 11 25 FEATURES 2 3 1 4 5 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Owners Manual
Page 48
... Low SPN 51 FMI 3 4 10 2 3 4 3 4 3 4 16 0 15 3 4 3 4 Vehicle Speed Sensor Intake Air Temperature Sensor Barometric Pressure Sensor Engine Temperature Sensor 84 105 108 110 Alternator Power Supply Potential (DC Chassis Voltage) Exhaust Temperature Sensor 167 173 44 Short-to-Ground: The wire is shorted to a wire at battery voltage. Shorted Load: The wires leading to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short...
... Low SPN 51 FMI 3 4 10 2 3 4 3 4 3 4 16 0 15 3 4 3 4 Vehicle Speed Sensor Intake Air Temperature Sensor Barometric Pressure Sensor Engine Temperature Sensor 84 105 108 110 Alternator Power Supply Potential (DC Chassis Voltage) Exhaust Temperature Sensor 167 173 44 Short-to-Ground: The wire is shorted to a wire at battery voltage. Shorted Load: The wires leading to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short...
Owners Manual
Page 49
FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Diagnostic Codes Component ECU Memory Injector 1 (MAG) (Port Injector) Injector 2 (PTO) (Port Injector) Knock Sensor 1 Ignition Coil Primary Driver 1 (MAG) Fuel Pump Driver Circuit Knock Level Cylinder 1 (MAG) Condition Checksum/CRC Error Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Open/Grounded Driver Circuit Short to B+ Voltage Too Low Driver Circuit Open/Grounded Driver Circuit Open/Grounded Maximum Detonation Correction Limit Reached Knock Above Critical Level Maximum...
FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Diagnostic Codes Component ECU Memory Injector 1 (MAG) (Port Injector) Injector 2 (PTO) (Port Injector) Knock Sensor 1 Ignition Coil Primary Driver 1 (MAG) Fuel Pump Driver Circuit Knock Level Cylinder 1 (MAG) Condition Checksum/CRC Error Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Open/Grounded Driver Circuit Short to B+ Voltage Too Low Driver Circuit Open/Grounded Driver Circuit Open/Grounded Maximum Detonation Correction Limit Reached Knock Above Critical Level Maximum...
Owners Manual
Page 83
... prevent any type of vehicle with the drive belt in the towed object. WARNING! Remove the drive belt before towing. 79 Braking distances increase when towing loads. OPERATION Daily Storage At the end of each ride, park the snowmobile on the towed snowmobile to operate the brake and steering when necessary. Towing For your safety, do not attempt to use a rigid tow bar, attach the tow rope to the...
... prevent any type of vehicle with the drive belt in the towed object. WARNING! Remove the drive belt before towing. 79 Braking distances increase when towing loads. OPERATION Daily Storage At the end of each ride, park the snowmobile on the towed snowmobile to operate the brake and steering when necessary. Towing For your safety, do not attempt to use a rigid tow bar, attach the tow rope to the...
Owners Manual
Page 84
... monitoring or controlling devices) should not be engaged during engine tune-ups. Environmental Protection Agency regulations. Specifications and adjustments for diagnostic service. Non-ionizing Radiation This vehicle emits some electromagnetic energy. People with a check engine light and it comes on, you must not be removed, even after you contact an authorized POLARIS dealer to perform any service that the specified maintenance is certified...
... monitoring or controlling devices) should not be engaged during engine tune-ups. Environmental Protection Agency regulations. Specifications and adjustments for diagnostic service. Non-ionizing Radiation This vehicle emits some electromagnetic energy. People with a check engine light and it comes on, you must not be removed, even after you contact an authorized POLARIS dealer to perform any service that the specified maintenance is certified...
Owners Manual
Page 88
... Toe Alignment Suspension Mounting Bolts Bolt Torques Steering Fasteners Rear Suspension Fasteners Rear Suspension Bushings Suspension Shock Oil Rear Shock Threads Cooling Fins and Shroud Skags (Wear Bars) Ski Saddle/Spindle Bolts Drive Chain Tension Hood and Side Panel Fasteners Rear Wheel Idler Bolts Idler Bolt Jam Nut Rear Suspension Pivot Shaft Camber Alignment Handlebar Centering Tether Switch and Strap Track Tension Track Alignment Front Limiter Strap Rail Slide Condition Chaincase Oil --I I I I I I I I See your POLARIS dealer for a bolt torque inspection every 1000 miles (1600...
... Toe Alignment Suspension Mounting Bolts Bolt Torques Steering Fasteners Rear Suspension Fasteners Rear Suspension Bushings Suspension Shock Oil Rear Shock Threads Cooling Fins and Shroud Skags (Wear Bars) Ski Saddle/Spindle Bolts Drive Chain Tension Hood and Side Panel Fasteners Rear Wheel Idler Bolts Idler Bolt Jam Nut Rear Suspension Pivot Shaft Camber Alignment Handlebar Centering Tether Switch and Strap Track Tension Track Alignment Front Limiter Strap Rail Slide Condition Chaincase Oil --I I I I I I I I See your POLARIS dealer for a bolt torque inspection every 1000 miles (1600...
Owners Manual
Page 103
... headlight. 2. Headlight Lamp Replacement 1. MAINTENANCE Lights When servicing a halogen lamp, avoid touching the lamp with denatured alcohol. Reinstall the connector to operate properly, replace the entire taillight assembly. 99 Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. If the light fails to the back of the lamp. Rotate the bulb 1/4 turn...
... headlight. 2. Headlight Lamp Replacement 1. MAINTENANCE Lights When servicing a halogen lamp, avoid touching the lamp with denatured alcohol. Reinstall the connector to operate properly, replace the entire taillight assembly. 99 Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. If the light fails to the back of the lamp. Rotate the bulb 1/4 turn...
Owners Manual
Page 118
MAINTENANCE Extended Storage Clutch and Drive System Remove the drive belt and store in the Master Repair Manual. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in a cool dry location. Engine Protection Proper preparation of the engine and fuel system is stored for five minutes to the fuel tank. Whenever the snowmobile is vital to the prevention of more than 60 days...
MAINTENANCE Extended Storage Clutch and Drive System Remove the drive belt and store in the Master Repair Manual. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in a cool dry location. Engine Protection Proper preparation of the engine and fuel system is stored for five minutes to the fuel tank. Whenever the snowmobile is vital to the prevention of more than 60 days...
Owners Manual
Page 120
SPECIFICATIONS 600 RUSH Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Gearcase Oil Capacity (oz./ml) Height Length Oil Capacity (qts./l) Designed Width (in./cm) Brake Type Drive Clutch Center Distance Drive Belt P/N Clutch Type Reverse Transmission Engine Displacement Cylinders Bore x Stroke (mm) Alternator Output Throttle Body Oil Injection Throttle Body Bore Size Idle RPM Cooling Ignition Type Ignition Timing Spark Plug / Gap Recommended Fuel Octane PRO-RIDE 1 5 qts. (4.7 l) 9 oz. (266.2 ml) 11 gal. (41.6 l) N/A 46 inches (117 ...
SPECIFICATIONS 600 RUSH Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Gearcase Oil Capacity (oz./ml) Height Length Oil Capacity (qts./l) Designed Width (in./cm) Brake Type Drive Clutch Center Distance Drive Belt P/N Clutch Type Reverse Transmission Engine Displacement Cylinders Bore x Stroke (mm) Alternator Output Throttle Body Oil Injection Throttle Body Bore Size Idle RPM Cooling Ignition Type Ignition Timing Spark Plug / Gap Recommended Fuel Octane PRO-RIDE 1 5 qts. (4.7 l) 9 oz. (266.2 ml) 11 gal. (41.6 l) N/A 46 inches (117 ...
Owners Manual
Page 122
SPECIFICATIONS 800 RUSH Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Gearcase Oil Capacity (oz./ml) Oil Capacity (qts./l) Height Length Designed Width (in./cm) Brake Type Drive Clutch Center Distance Drive Belt P/N Clutch Type Reverse Transmission Engine Displacement Cylinders Bore x Stroke (mm) Alternator Output Throttle Body Oil Injection Throttle Body Bore Size Idle RPM Cooling Ignition Type Ignition Timing Spark Plug / Gap Recommended Fuel Octane PRO-RIDE 1 5 qts. (4.7 l) 9 oz. (266.2 ml) 11 gal. (41.6 l) N/A 3.8 qts. (3.6 ...
SPECIFICATIONS 800 RUSH Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Gearcase Oil Capacity (oz./ml) Oil Capacity (qts./l) Height Length Designed Width (in./cm) Brake Type Drive Clutch Center Distance Drive Belt P/N Clutch Type Reverse Transmission Engine Displacement Cylinders Bore x Stroke (mm) Alternator Output Throttle Body Oil Injection Throttle Body Bore Size Idle RPM Cooling Ignition Type Ignition Timing Spark Plug / Gap Recommended Fuel Octane PRO-RIDE 1 5 qts. (4.7 l) 9 oz. (266.2 ml) 11 gal. (41.6 l) N/A 3.8 qts. (3.6 ...
Owners Manual
Page 126
... non-ethanol fuel at all times for spark. TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Poor fuel Not enough fuel getting to engine Plugged fuel filter or tank pick-up sock Incorrect clutching Engine continually backfires Faulty plug(s) Fuel System Incorrect throttle freeplay or faulty switch Engine requires more than normal pulls to start Probable Cause Solution Faulty ignition • Install new spark plug(s). If there's no spark, SEE YOUR DEALER. • Make sure the fuel valve is...
... non-ethanol fuel at all times for spark. TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Poor fuel Not enough fuel getting to engine Plugged fuel filter or tank pick-up sock Incorrect clutching Engine continually backfires Faulty plug(s) Fuel System Incorrect throttle freeplay or faulty switch Engine requires more than normal pulls to start Probable Cause Solution Faulty ignition • Install new spark plug(s). If there's no spark, SEE YOUR DEALER. • Make sure the fuel valve is...
Owners Manual
Page 129
... of your snowmobile and its engine. Administration 1. POLARIS snowmobile owner reports theft. B. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual. Previous correspondence Use the page provided near the front of your POLARIS dealer for replacement parts, service or warranty. A. Dealer name 4. Length of time and conditions of all stolen units...
... of your snowmobile and its engine. Administration 1. POLARIS snowmobile owner reports theft. B. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual. Previous correspondence Use the page provided near the front of your POLARIS dealer for replacement parts, service or warranty. A. Dealer name 4. Length of time and conditions of all stolen units...
Owners Manual
Page 131
... from state to perform warranty service. Please work with controlling state law. This warranty gives you specific legal rights, and you if inconsistent with your original selling dealer; Some states do not allow limitations on how long an implied warranty lasts, so the above terms are void because of a POLARIS retail program, please contact any warranty issues. Engine Oil 1. Mixing oil brands or using...
... from state to perform warranty service. Please work with controlling state law. This warranty gives you specific legal rights, and you if inconsistent with your original selling dealer; Some states do not allow limitations on how long an implied warranty lasts, so the above terms are void because of a POLARIS retail program, please contact any warranty issues. Engine Oil 1. Mixing oil brands or using...
Owners Manual
Page 132
... an effective repair. failure due to friction surfaces, stresses, environmental conditions and/or contamination. Failure to provide proof of a defect: Skis Tracks Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Idler wheels Ski wear rods Slide rails Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Warranty applies to...
... an effective repair. failure due to friction surfaces, stresses, environmental conditions and/or contamination. Failure to provide proof of a defect: Skis Tracks Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Idler wheels Ski wear rods Slide rails Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Warranty applies to...
Owners Manual
Page 133
...this vehicle's warranty or service bulletin coverage if you should take your vehicle. Upon residence verification, the servicing dealer will be authorized to Safety Bulletins. WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF ...country where your vehicle was purchased: Warranty or Service Bulletin repairs must show the dealer photo identification from the country of residence. Dealers may be done by an authorized POLARIS dealer. This policy does not apply to perform the warranty repair. 129 If...
...this vehicle's warranty or service bulletin coverage if you should take your vehicle. Upon residence verification, the servicing dealer will be authorized to Safety Bulletins. WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF ...country where your vehicle was purchased: Warranty or Service Bulletin repairs must show the dealer photo identification from the country of residence. Dealers may be done by an authorized POLARIS dealer. This policy does not apply to perform the warranty repair. 129 If...
Owners Manual
Page 135
... for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components for evaporative emissions Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector *As related to the POLARIS...
... for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components for evaporative emissions Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector *As related to the POLARIS...
Owners Manual
Page 140
... Coolant Level...91 Cooling System ...91-93 Cooling System, Bleeding ...93 Cooling System, Flushing ...92 Customer Service...125 E Electrical Connections, Storage ...114 Emission Control Information...80 Emissions Limited Warranty...131-132 Engine Break-In ...68-69 Engine Overheating...92 Engine Protection for Storage ...114 Engine Restarting ...67 Engine Safety ...10 Engine Starting ...67 Engine Stop Switch ...74 Environment Preservation...6 Exhaust System ...94 F Fasteners, Hood and Side Panel ...65 Fluid Change Chaincase ...86 Coolant ...92 Fluid Level Brake Fluid...
... Coolant Level...91 Cooling System ...91-93 Cooling System, Bleeding ...93 Cooling System, Flushing ...92 Customer Service...125 E Electrical Connections, Storage ...114 Emission Control Information...80 Emissions Limited Warranty...131-132 Engine Break-In ...68-69 Engine Overheating...92 Engine Protection for Storage ...114 Engine Restarting ...67 Engine Safety ...10 Engine Starting ...67 Engine Stop Switch ...74 Environment Preservation...6 Exhaust System ...94 F Fasteners, Hood and Side Panel ...65 Fluid Change Chaincase ...86 Coolant ...92 Fluid Level Brake Fluid...
Owners Manual
Page 141
... Inadequate Snow Conditions ...16 Independent Front Suspension ...50 Indicator Lights...31 Information Display Area ...34 Inspection, Pre-Ride ...60 Instrument Cluster...30-45 Intake Filters ...87 Intake Silencer ...18 P Parking Brake Lever Lock ...64 Passenger Warning ...22 Playback Function ...35 Polaris Products and Part Numbers . 115 Preload, Front Track Shock Spring . . 54 Preload, IFS Shock Spring ...51 Preload, Rear Shock Spring ...55 Pre-Ride Checklist ...60 Pre-Ride Suspension Inspection...61 Pressure Cap Warning ...21...
... Inadequate Snow Conditions ...16 Independent Front Suspension ...50 Indicator Lights...31 Information Display Area ...34 Inspection, Pre-Ride ...60 Instrument Cluster...30-45 Intake Filters ...87 Intake Silencer ...18 P Parking Brake Lever Lock ...64 Passenger Warning ...22 Playback Function ...35 Polaris Products and Part Numbers . 115 Preload, Front Track Shock Spring . . 54 Preload, IFS Shock Spring ...51 Preload, Rear Shock Spring ...55 Pre-Ride Checklist ...60 Pre-Ride Suspension Inspection...61 Pressure Cap Warning ...21...
Owners Manual
Page 142
... Switch ...30 Throttle Safety Switch...74 S Safety Labels ...21-23 Safety Symbols ...8 Security System ...29, 37-42 Set-Up Guide, Suspension ...46-49 Shock Clicker, Rear Shock ...55 Shock Clicker, Rebound (800 LE)...52 Shock Lubrication, Rear Shock ...85 Shock Springs, Rear...48 Shock Valving, IFS ...52 Side Panel Access ...85 Side Panel Fasteners ...65 Signal Words ...8 Skags, Carbide ...59 Ski Alignment ...110 Ski Skags ...111 Slide Rail and Track Cooling ...70 Snow Conditions ...16 Spark Plug Condition...89 Spark Plug...
... Switch ...30 Throttle Safety Switch...74 S Safety Labels ...21-23 Safety Symbols ...8 Security System ...29, 37-42 Set-Up Guide, Suspension ...46-49 Shock Clicker, Rear Shock ...55 Shock Clicker, Rebound (800 LE)...52 Shock Lubrication, Rear Shock ...85 Shock Springs, Rear...48 Shock Valving, IFS ...52 Side Panel Access ...85 Side Panel Fasteners ...65 Signal Words ...8 Skags, Carbide ...59 Ski Alignment ...110 Ski Skags ...111 Slide Rail and Track Cooling ...70 Snow Conditions ...16 Spark Plug Condition...89 Spark Plug...