Polaris 600 Indy Owner's Manual
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Polaris 600 Indy Owner's Manual

Maintenance and safety
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PMS 419
600 INDY
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  • Page 1 PMS 419 600 INDY 800 INDY Snowmobile Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 4 INDY® PERC® Copyright 2013 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result between the actual vehicle and the information presented in this publi- cation.

  • Page 5: Table Of Contents

    Specifications ......106 POLARIS Products..... 110 Troubleshooting .

  • Page 7: Introduction

    INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations.

  • Page 8: Air Pollution

    POLARIS snowmobiles are engineered to conform to these SAE stan- dards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others.

  • Page 9: Vehicle Identification Numbers

    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 lost, the ignition switch must be replaced.

  • Page 10: Safety

    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 injury hazard. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
  • Page 11 Always check major and vital safety components before every ride. All POLARIS snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.

  • Page 12: Riding Position

    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.

  • Page 13: Riding Apparel

    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 estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 14: Disabled Operators

    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 your safety, always ride in a group of other snowmobilers.

  • Page 15: Rider Capacity

    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 inclement weather. Always observe all state and local laws governing snowmobile opera- tion and speed limits.

  • Page 16: Driver Awareness

    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.
  • Page 17 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.

  • Page 18: Ice And Snow Build-Up

    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 are not interfering with full left and right steering.

  • Page 19: Driving Downhill

    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 downhill.

  • Page 20: Drive Belt

    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.

  • Page 21: Driving Responsibly

    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 conditions. Even seasoned driv- ers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.
  • Page 22 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) Wind Actual Thermometer Reading (°F) Speed -10 -15 -20 -25 -30 -35 -40 -45 Equivalent Temperature (°F) Calm -10 -15 -20 -25 -30 -35 -40 -45 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63...

  • Page 23: Clutch Warning

    If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are pro- vided by POLARIS at no charge. The part number is printed on the label. Clutch Warning...
  • Page 24 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. Reverse Warning No Passenger Warning/Fuel Recommendation Label...

  • Page 25: Hot Surface Warning

    Hot Surface Warning WARNING Hot Surface Do Not Touch Burns may result. Entire top of tunnel may be hot. Install only accessories specifically Track approved for this model by Warning POLARIS.
  • Page 26 • To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, con- tact a POLARIS dealer for a replacement. • This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control.
  • Page 27 SAFETY Safety Labels and Locations Operation Warning • When operating with a passenger (on approved models only) reduce speed and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle. • When operating on hard-packed snow, ice, or when crossing roads, steering and braking ability are greatly reduced.

  • Page 28: Features

    FEATURES 1. Nosepan 9. Operator Seat 2. Skis 10. Taillight 3. Front Bumper 11. Rear Bumper 4. Hood 12. Snow Flap 5. Headlight 13. Suspension 6. Windshield (accessory) 14. Track 7. Handlebar 15. Side Panel 8. Fuel Filler Cap 16. Side Panel Fasteners...

  • Page 29: Features

    FEATURES 1. Instrument Cluster 2. Ignition Switch 3. Engine Stop Switch 4. Recoil Starter Handle 5. Brake Lever 6. Parking Brake Lock 7. Handlebar Grip Warmer Switch 8. Thumbwarmer Switch 9. Electronic Reverse Button 10. MODE/SET Switch 11. Headlight Dimmer Switch 12.

  • Page 30: Features

    Do not exceed the weight limit. 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 snowmo- bile. Use of unapproved parts and accessories may result in: •...

  • Page 31: Features

    FEATURES Fuel Type Selection Whenever using ethanol, MTBE or other forms of oxygenated gaso- lines, 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 purchase, use the “ETH”...

  • Page 32: Features

    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 engine performance and RPM when the DET system is activated.

  • Page 33: Features

    Low fuel/no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel filter or tank pick-up sock See your POLARIS dealer for service Alcohol-based fuel additive used with Do not add deicers or additives that Ethanol fuel...

  • Page 34: Features

    FEATURES Instrument Cluster Indicator Speedometer Lamps Rider MODE Information Button Center 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 off any gasoline that splashes on the instrument cluster.

  • Page 35: Features

    FEATURES Instrument Cluster Indicator Lamps Lamp Indicates Condition When standard mode is selected, speed Vehicle Speed displays in miles per hour. When metric mode is selected, speed displays in kilometers per hour. Reverse This indicator flashes when the transmis- sion is in reverse. See page 71. High Beam The high beam indicator illuminates when the lights are set to high beam.

  • Page 36: Features

    FEATURES Instrument Cluster 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 handle- bar. Setting changes must be made with the engine running or with the vehicle powered by an external DC power supply connector.

  • Page 37: Features

    FEATURES Instrument Cluster 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. Standard Display Metric Display Distance Miles...
  • Page 38 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 unauthorized use when leaving the snowmobile unattended.

  • Page 39: Features

    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 unauthorized use when leaving the snowmobile unattended.

  • Page 40: Features

    FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) First Time Use of Your Security System TASK 3: Unlock the System 1. When the engine is running, the display will alternate between SECURE ON and ENTER. Wait until ENTER displays, then press and release SET to advance the digit.

  • Page 41: Features

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

  • Page 42: Features

    FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Unlocking the System With Your Personal Security Code 1. When the engine is running, the display will alternate between SECURE ON and ENTER. Wait until ENTER displays, then press and release SET to advance the digit. When the first digit of your security code is displayed, press and release MODE to accept the digit.

  • Page 43: Features

    FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Changing to a New Security Code Any time you wish to change your current security code to a new code, perform TASK 2 through TASK 4 of the First Time Use of Your Secu- rity System procedure beginning on page 37.

  • Page 44: Features

    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 engine if you want to view an error code. When the engine is stopped, any codes are stored in the history of the electronic control unit (ECU).

  • Page 45: Features

    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 control unit and the item listed in the chart.

  • Page 46: Features

    FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Diagnostic Codes Component Condition ECU Memory Checksum/CRC Error Injector 1 (MAG) (Port Injector) Driver Circuit Open/Grounded Driver Circuit Short to B+ Injector 2 (PTO) (Port Injector) Driver Circuit Open/Grounded Driver Circuit Short to B+ Knock Sensor 1 Voltage Too Low Ignition Coil Primary Driver 1 (MAG)

  • Page 47: The Perfect Fit

    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 exhausted and rider weight is at the very high or very low weight range for the stock spring, additional adjustments are possible to the IFS.
  • Page 48 Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a POLARIS dealer.

  • Page 49: Suspension Performance Tips

    Bogie wheel kits are available from your dealer. • POLARIS offers track kits for improved flotation in deep snow. See your dealer for assistance. Tip: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.
  • Page 50 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 full exten- sion.

  • Page 51: Torsion Spring Preload

    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 require significantly more effort.

  • Page 52: Suspension Coupling

    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.
  • Page 53 THE PERFECT FIT Rear Suspension Adjustments Suspension Coupling 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 torque arm.
  • Page 54 THE PERFECT FIT Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling HIGH weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. MEDIUM To decrease weight transfer under acceleration (for improved corner-...

  • Page 55: Traction Products

    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 steering and control.

  • Page 56: Handlebar Adjustments

    THE PERFECT FIT Handlebar Adjustments Handlebar Position (if equipped) 1. Loosen the four bolts on the Loosen top bolts to adjust bottom of the adjuster block. If handlebar angle necessary, pry the blocks apart with a screwdriver. 2. Adjust the handlebar forward or rearward to the desired posi- tion.

  • Page 57: Pre-Ride Inspections

    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. Item See Page Drive Belt Condition Steering System Recoil Rope Coolant Level Chaincase Oil Level Injection Oil Level Parking Brake Lock/Brake Lever/Brake System...

  • Page 58: Pre-Ride Suspension Inspection

    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 before any long trip. Item Check Page...

  • Page 59: Throttle Lever

    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 malfunctioning components could result in serious injury or death.
  • Page 60 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 1/2 in. (1.3 cm) handgrip than 1/2 inch (1.3 cm).

  • Page 61: Parking Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1.
  • Page 62 Recoil Rope Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your POLARIS dealer for replacement.

  • Page 63: Ignition Switch

    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. See Before Starting the Engine beginning on page 57.

  • Page 64: Operation

    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.

  • Page 65: Break-In Period

    Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. Oils may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All POLARIS oils are compatible with each other. Initial Fuel Premix Always premix fuel in 5-gallon (19-liter) increments in a separate fuel container.

  • Page 66: Oil Injection System

    NOTICE: Use of any lubricants other than those recommended by POLARIS may cause serious engine damage. We recommend the use of POLARIS lubricants for your vehicle.

  • Page 67: Slide Rail And Track Cooling

    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 the track is free-hanging.
  • Page 68 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 tank neck. •...

  • Page 69: Fuel Recommendation

    Never use deicers or additives containing methanol. POLARIS recommends the use of Carbon Clean. See page 110 for the part numbers of POLARIS prod- ucts. If you use fuel with up to 10% ethanol (sometimes labeled “oxygen-...

  • Page 70: Low Oil Level

    NOTICE: Operating the snowmobile without adequate engine lubrication can result in serious engine damage. Always check the oil level when refu- eling. Add oil as needed. The oil bottle cap is vented to allow proper oil flow. See your POLARIS dealer for recommended replacement parts.

  • Page 71: Engine Stop Switch

    OPERATION Engine Stop Switch Push down on the engine stop switch to ground out the Stop ignition and stop the engine Switch 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 from the throttle lever and the throttle cable or valves do not return to the normal closed position.
  • Page 72 When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the snowmobile with the throttle safety switch disconnected. Return the snowmobile to an authorized POLARIS dealer for service as soon as possible.
  • Page 73 OPERATION Electronic Reverse (PERC) WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or trans- mission if shifting is attempted when the engine is operating above idle speed. •...

  • Page 74: Emergency Stopping

    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 running. 2.
  • Page 75 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 inches (10 cm) off the ground. Remove the key and cover the snowmobile.

  • Page 76: Maintenance

    Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsi- ble for ensuring that the specified maintenance is performed. POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary.
  • Page 77 If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfort- able performing these tasks yourself, contact an authorized POLARIS dealer for service. NOTICE: Hot components can cause damage to plastic. Always make sure the exhaust system and engine have cooled before tipping the snowmo- bile on its side for service or inspection.
  • Page 78 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 dealer. Item Frequency Page 150 mi.
  • Page 79 MAINTENANCE Periodic Maintenance Interval Table Item Frequency Page 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System 58, 90 Brake Fluid FUEL MANAGEMENT...
  • Page 80 I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Bolt Torque Inspection To maintain proper chassis performance, see your POLARIS dealer for a bolt torque inspection every 1000 miles (1600 km). Item Description Engine Mounting Bolts...
  • Page 81 To remove an open side panel, pull the panel outward to release the tabs at the lower edge of the panel. Removing the hood is not recommended. Any service requiring the removal of the hood should be performed by an authorized POLARIS dealer.

  • Page 82: Rear Suspension

    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 76 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

  • Page 83: Chaincase Oil

    75. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Syn- thetic Chaincase Lube. See page 110 for the part numbers of POLARIS products. Oil Level Fill Plug 1.

  • Page 84: Spark Plugs

    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 the specifications section for the specific spark plug to be used in your snowmobile.

  • Page 85: Spark Plug Inspection

    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.

  • Page 86: Intake Filters

    Do not attempt to service the fuel pump. Fuel Filter/Fuel Lines See your POLARIS dealer for replacement of the fuel filter at the inter- vals outlined in the Periodic Maintenance Table beginning on page 76. Contaminated or poor quality fuel will shorten the life of the fuel filter and result in poor engine performance.

  • Page 87: Cooling System

    POLARIS Antifreeze 60/40 Premix. POLARIS Antifreeze is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture. See page 110 for POLARIS prod- ucts. Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.

  • Page 88: Engine Overheating

    This service must be performed when the engine is cold. Ask your POLARIS dealer to check the coolant when he performs the fall tune-up on your snowmobile.
  • Page 89 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.

  • Page 90: Exhaust System

    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.

  • Page 91: Drive Chain Tension

    MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. 1. Remove the side panels. 2. Rotate the driven clutch coun- ter-clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.

  • Page 92: Brake Components

    1/16 inch or 1.5 mm). 4. Anti-rattle springs (come with brake pad kit) Excessive Lever Travel Hydraulic brakes are self-adjust- ing, but if excessive brake pad clearance develops, bring the snowmobile to an authorized POLARIS dealer for inspection and adjustment.

  • Page 93: Brake Fluid

    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 POLARIS DOT 4 high temperature brake fluid. See page 110 for the part numbers of POLARIS products.
  • Page 94 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 lead to serious injury or death.

  • Page 95: Headlight Lamp Replacement

    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.

  • Page 96: Clutch Alignment Offset

    POLARIS dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. NOTICE: The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated. Do not lubri- cate clutch bushings.

  • Page 97: Drive Belt Condition

    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.

  • Page 98: Drive Belt Removal

    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 forward engagement before attempting to remove the belt.
  • Page 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 rear of the snow- mobile off the ground.
  • Page 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 is critical for proper handling.
  • Page 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 If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7.

  • Page 102: Track Alignment

    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.

  • Page 103: Steering Inspection

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

  • Page 104: Ski Alignment

    WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your POLARIS dealer. 1. Place the handlebars in a straight-ahead position.

  • Page 105: Ski Skags

    4. Remove the rear end of the skag. Skag 5. Reverse the steps to install a skag. Rail Slide Wear For ease of inspection, all POLARIS rail slides have a wear limit indicator groove to indicate the minimum permissible slide thickness. Replace the rail slides if Minimum...

  • Page 106: Transporting The Snowmobile

    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 110 for the part numbers of POLARIS products. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, side panels, chassis, and plastic parts.

  • Page 107: Controls And Linkage

    MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Mainte- nance Table beginning on page 76. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual.

  • Page 108: Specifications

    SPECIFICATIONS 600 INDY Capacities and Dimensions Body Style PRO-RIDE Rider Capacity 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 Oil Capacity 3.8 qts. (3.6 l) Height 48 in.
  • Page 109 SPECIFICATIONS 600 INDY (Non-Electric Start Models) Clutching Chart ALTITUDE Chaincase Drive Clutch Drive Clutch Driven Clutch Driven Meters Gearing/ Shift Weight Spring Spring Helix (Feet) Pitch *Shaded cells indicate factory settings. (58/42/.45) 0-600 10-64 120/310 Black 130/180 P2 Tab 22:40...
  • Page 110 SPECIFICATIONS 800 INDY Capacities and Dimensions Body Style PRO-RIDE Rider Capacity 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 Oil Capacity 3.8 qts. (3.6 l) Height 48 in.
  • Page 111 SPECIFICATIONS 800 INDY Clutching Chart ALTITUDE Chaincase Drive Clutch Drive Clutch Driven Clutch Driven Meters Gearing/ Shift Weight Spring Spring Helix (Feet) Pitch *Shaded cells indicate factory settings. (64/42/.36) 0-600 10-66 120/310 Black Red/Black Team 23:39 (0-2000) (1321584) (7043681) (7043058) 72 Pitch ER (5135401) (64/42/.36)

  • Page 112: Polaris Products

    All Season Grease (3 oz./89 ml cartridge) 2871423 All Season Grease (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel™) Coolant 2871534 Polaris Antifreeze 60/40 Premix (qt./.95 l) 2871323 Polaris Antifreeze 60/40 Premix (gal./3.8 l) Additives/Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer...

  • Page 113: Troubleshooting

    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- Drive clutch binding • SEE YOUR DEALER. ating RPM during Driven clutch • SEE YOUR DEALER. acceleration or load malfunction variations...
  • Page 114 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch • SEE YOUR DEALER. system components Bearing failure/ • SEE YOUR DEALER. chaincase, jackshaft, or front drive shaft Drive belt surface • Inspect and replace as needed. flat spots Drive chain loose •...
  • Page 115 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails Faulty ignition • Install new spark plug(s). If engine to start still fails to start, check for spark. If there's no spark, SEE YOUR DEALER. No fuel to engine •...
  • Page 116 TROUBLESHOOTING Rear Suspension Troubleshooting Problem Solution Rear suspension • Adjust torsion spring preload to achieve proper static sag bottoms too easily (see page 48). • Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear track shock (see your dealer). •...
  • Page 117 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 weather and warm it up.

  • Page 118: Warranty

    Your dealer receives frequent updates on changes, modifi- cations and tips on snowmobile maintenance, which may supersede informa- tion contained in this manual. Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you.
  • Page 119 POLARIS warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. POLARIS warranty will aid in notifying the proper owner when a unit is recovered.
  • Page 120 POLARIS' control. This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the snowmobile.
  • Page 121 • Two-year extended engine coverage • Two-year powertrain coverage • Extended service contract If you selected any type of extended warranty coverage as part of a POLARIS retail pro- gram, please contact any authorized POLARIS dealer for additional information. How to Obtain Warranty Service If your snowmobile requires warranty service, you must take it to a POLARIS dealer authorized to repair POLARIS snowmobiles.
  • Page 122 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 vehi- cle Pre-Delivery Inspection, perform all applicable service bulletins and have the con- sumer sign the PDI form prior to delivery may void the warranty.
  • Page 123 You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and...
  • Page 124 How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle.
  • Page 125 This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 126 POLARIS dealer to perform any service that may be necessary for your vehi- cle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 127: Maintenance Log

    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 TECHNICIAN SERVICE PERFORMED / COMMENTS (KM) 150 mi.
  • Page 128 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 129: Index

    INDEX Accessories ....28 Drive Belt Air Pollution ....6 Break-In .
  • Page 130 IFS ......45 Polaris Products and Part Numbers . 110 IFS Adjustment Options ..45 Preload, IFS Shock Spring.
  • Page 131 INDEX Safety Labels....21-24 Tachometer ....35 Safety Symbols .
  • Page 132 PMS 419 For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polaris.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9924256 Rev 01 Printed in USA *9924256...

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