Owners Manual
Page 12
... perform all track service and alignment procedures. Turn off the ignition, open the side panels or hood, make the adjustment, secure shields and guards, secure the side panels and hood, and then restart the engine to check its operation. Do not stand on the handlebar grips for proper throttle, brake and steering control. Serious injuries may reduce control and could cause serious injury or death. WARNING...
... perform all track service and alignment procedures. Turn off the ignition, open the side panels or hood, make the adjustment, secure shields and guards, secure the side panels and hood, and then restart the engine to check its operation. Do not stand on the handlebar grips for proper throttle, brake and steering control. Serious injuries may reduce control and could cause serious injury or death. WARNING...
Owners Manual
Page 18
... and/or engine. Avoid operating for operation of your snowmobile, resulting in serious injury or death. Driving on ice, hard-packed surfaces or roads. Proceed slowly and use extra caution when operating on ice or hardpacked snow reduces steering and braking control, which can result in serious injury. Ice and snow build-up WARNING! WARNING! Before driving, manually turn the skis...
... and/or engine. Avoid operating for operation of your snowmobile, resulting in serious injury or death. Driving on ice, hard-packed surfaces or roads. Proceed slowly and use extra caution when operating on ice or hardpacked snow reduces steering and braking control, which can result in serious injury. Ice and snow build-up WARNING! WARNING! Before driving, manually turn the skis...
Owners Manual
Page 21
... (follow too closely). SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may injure your vehicle. Check to see if they take a snowmobile safety course. Drive defensively to avoid accidents. • Remove the key from the ignition when you 're new to provide protection from the course. • Don't "jump" your speed. • When traveling...
... (follow too closely). SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may injure your vehicle. Check to see if they take a snowmobile safety course. Drive defensively to avoid accidents. • Remove the key from the ignition when you 're new to provide protection from the course. • Don't "jump" your speed. • When traveling...
Owners Manual
Page 25
... stop . • To maintain vehicle control on the top of control. Check oil level when refueling. 23 See Owner's Manual for proper use only. Then pull the brake lever to turn or stop the engine. Do not leave brake engaged for more than five minutes. • Before starting engine, check throttle, brake, and steering for a replacement. • This vehicle is missing, contact a POLARIS dealer for proper operation. Reduce...
... stop . • To maintain vehicle control on the top of control. Check oil level when refueling. 23 See Owner's Manual for proper use only. Then pull the brake lever to turn or stop the engine. Do not leave brake engaged for more than five minutes. • Before starting engine, check throttle, brake, and steering for a replacement. • This vehicle is missing, contact a POLARIS dealer for proper operation. Reduce...
Owners Manual
Page 53
SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch WHAT IT DOES Interrupts ignition circuit Slows jackshaft Floods engine Interrupts ignition circuit Interrupts ignition circuit THROTTLE CONDITION All All Half throttle or less All All All Tether Switch (accessory) Interrupts ignition circuit 51 OPERATION Emergency Stopping The following chart lists methods for more information about the engine stop switch and throttle safety switch. See page 59 for stopping the snowmobile in the event of an emergency.
SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch WHAT IT DOES Interrupts ignition circuit Slows jackshaft Floods engine Interrupts ignition circuit Interrupts ignition circuit THROTTLE CONDITION All All Half throttle or less All All All Tether Switch (accessory) Interrupts ignition circuit 51 OPERATION Emergency Stopping The following chart lists methods for more information about the engine stop switch and throttle safety switch. See page 59 for stopping the snowmobile in the event of an emergency.
Owners Manual
Page 61
... ground out the ignition and stop the engine quickly. Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the illustration. 4. Test the throttle safety switch system daily before operation. 1. Sit on the seat. 2. Apply a slight amount of an accident. Start the engine and allow restarting. A properly functioning switch must shut down the engine. 59 WARNING! Do not start the engine...
... ground out the ignition and stop the engine quickly. Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the illustration. 4. Test the throttle safety switch system daily before operation. 1. Sit on the seat. 2. Apply a slight amount of an accident. Start the engine and allow restarting. A properly functioning switch must shut down the engine. 59 WARNING! Do not start the engine...
Owners Manual
Page 65
... vehicle with the drive belt in place can easily collide with an appropriate track stand. Remove the key and cover the snowmobile. Slow down to the steering components. If the snowmobile becomes inoperable and must be used. Always remove the drive belt from a disabled snowmobile before towing, and have no braking power and can result in serious damage to the engine and drive...
... vehicle with the drive belt in place can easily collide with an appropriate track stand. Remove the key and cover the snowmobile. Slow down to the steering components. If the snowmobile becomes inoperable and must be used. Always remove the drive belt from a disabled snowmobile before towing, and have no braking power and can result in serious damage to the engine and drive...
Owners Manual
Page 66
... performed. The ECI label is permanently affixed to a qualified dealer for ensuring that the specified maintenance is equipped at the time of the tunnel or the engine recoil cover. You may remove the factory-installed emissions information hangtag, which is certified to your owner's manual. MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control...
... performed. The ECI label is permanently affixed to a qualified dealer for ensuring that the specified maintenance is equipped at the time of the tunnel or the engine recoil cover. You may remove the factory-installed emissions information hangtag, which is certified to your owner's manual. MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control...
Owners Manual
Page 70
... mi. (1600 km) 2000 mi. (3200 km) PreSeason CHASSIS Ski Toe Alignment Suspension Mounting Bolts Bolt Torques Rear Suspension Fasteners Steering Fasteners Cooling Fan / Ducts / Bulkhead Vent Skags (Wear Bars) Ski Saddle/Spindle Bolts Steering Arm(s) Drive Chain Tension Hood and Side Panel Fasteners Rear Wheel Idler Bolts Idler Bolt Jam Nut Handlebar Centering Tether Switch and Strap Track Alignment Track Tension Front Limiter Strap Rail Slide Condition Chaincase Oil --I I I I I I I I - Inspect (clean, adjust, tighten, lubricate...
... mi. (1600 km) 2000 mi. (3200 km) PreSeason CHASSIS Ski Toe Alignment Suspension Mounting Bolts Bolt Torques Rear Suspension Fasteners Steering Fasteners Cooling Fan / Ducts / Bulkhead Vent Skags (Wear Bars) Ski Saddle/Spindle Bolts Steering Arm(s) Drive Chain Tension Hood and Side Panel Fasteners Rear Wheel Idler Bolts Idler Bolt Jam Nut Handlebar Centering Tether Switch and Strap Track Alignment Track Tension Front Limiter Strap Rail Slide Condition Chaincase Oil --I I I I I I I I - Inspect (clean, adjust, tighten, lubricate...
Owners Manual
Page 85
... the bulb. 4. Peel back the foam shield covering the headlight assembly. 2. Secure the foam shield. Oil from the back of the headlight. 3. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. 6. Apply dielectric grease to operate properly, replace the entire taillight assembly. 83 Taillight/Brake Light Replacement The taillight assembly is not serviceable. Headlight Lamp Replacement 1.
... the bulb. 4. Peel back the foam shield covering the headlight assembly. 2. Secure the foam shield. Oil from the back of the headlight. 3. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. 6. Apply dielectric grease to operate properly, replace the entire taillight assembly. 83 Taillight/Brake Light Replacement The taillight assembly is not serviceable. Headlight Lamp Replacement 1.
Owners Manual
Page 99
... very poor slow speed driving quality. Be sure wiring harness is vital to the fuel tank. 2. See your dealer. Run the engine for a period of rust and corrosion on precision engine parts during summer storage. MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Master Repair Manual. Clutch and Drive System Remove the drive belt and store in a cool dry location. Engine and Carburetor...
... very poor slow speed driving quality. Be sure wiring harness is vital to the fuel tank. 2. See your dealer. Run the engine for a period of rust and corrosion on precision engine parts during summer storage. MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Master Repair Manual. Clutch and Drive System Remove the drive belt and store in a cool dry location. Engine and Carburetor...
Owners Manual
Page 100
SPECIFICATIONS 550 INDY 121 Capacities and Dimensions Body Style Rider Capacity Chaincase Oil Capacity Fuel Capacity Oil Capacity Gearcase Oil Capacity Height Length Designed Width Brake Type Drive Clutch Center Distance Drive Belt P/N Drive Clutch Type/Driven Clutch Type Reverse Transmission Engine Displacement Cylinders Bore x Stroke (mm) Alternator Output Carburetor/Throttle Body Carburetor Model Idle RPM Rated Operating RPM Cooling Ignition Type Ignition Timing Spark Plug / Gap Recommended Engine Oil Recommended Fuel Octane Main Jet Pilot Jet Jet Needle/Clip Position Needle Jet Cutaway ...
SPECIFICATIONS 550 INDY 121 Capacities and Dimensions Body Style Rider Capacity Chaincase Oil Capacity Fuel Capacity Oil Capacity Gearcase Oil Capacity Height Length Designed Width Brake Type Drive Clutch Center Distance Drive Belt P/N Drive Clutch Type/Driven Clutch Type Reverse Transmission Engine Displacement Cylinders Bore x Stroke (mm) Alternator Output Carburetor/Throttle Body Carburetor Model Idle RPM Rated Operating RPM Cooling Ignition Type Ignition Timing Spark Plug / Gap Recommended Engine Oil Recommended Fuel Octane Main Jet Pilot Jet Jet Needle/Clip Position Needle Jet Cutaway ...
Owners Manual
Page 104
Engine doesn't turn Hydrostatic lock Engine doesn't start (electric start models) Wire connections 102 TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive system Probable Cause Solution Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain worn, sprocket teeth broken • SEE YOUR DEALER. • SEE YOUR DEALER. • Inspect and replace as needed . • Inspect and adjust (or replace). • SEE YOUR DEALER. Drain plug(s) are located...
Engine doesn't turn Hydrostatic lock Engine doesn't start (electric start models) Wire connections 102 TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive system Probable Cause Solution Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain worn, sprocket teeth broken • SEE YOUR DEALER. • SEE YOUR DEALER. • Inspect and replace as needed . • Inspect and adjust (or replace). • SEE YOUR DEALER. Drain plug(s) are located...
Owners Manual
Page 108
... 4. Previous correspondence Use the page provided near the front of operation 7. 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. When contacting us about parts, service, or warranty, always provide the following information: 1. Length of time and conditions of your owner's manual to assist you. Contact your snowmobile and its engine.
... 4. Previous correspondence Use the page provided near the front of operation 7. 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. When contacting us about parts, service, or warranty, always provide the following information: 1. Length of time and conditions of your owner's manual to assist you. Contact your snowmobile and its engine.
Owners Manual
Page 110
...: Skis Tracks Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Idler wheels Sealants Coolant Fuel Ski wear rods Slide rails Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Spark Plugs Lubricants Filters 108 repairs made after the warranty period expires or by external stress, heat, cold or contamination; This warranty also does not cover any failures...
...: Skis Tracks Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Idler wheels Sealants Coolant Fuel Ski wear rods Slide rails Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Spark Plugs Lubricants Filters 108 repairs made after the warranty period expires or by external stress, heat, cold or contamination; This warranty also does not cover any failures...
Owners Manual
Page 112
... under your name and address with a local POLARIS dealer in your new country immediately after you move to another country, be authorized to perform the warranty repair. however, you may be denied. You must take your product to an authorized POLARIS dealer. WARRANTY How to Obtain Warranty Service If your vehicle requires warranty service, you must show the dealer photo identification...
... under your name and address with a local POLARIS dealer in your new country immediately after you move to another country, be authorized to perform the warranty repair. however, you may be denied. You must take your product to an authorized POLARIS dealer. WARRANTY How to Obtain Warranty Service If your vehicle requires warranty service, you must show the dealer photo identification...
Owners Manual
Page 114
... 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 119
... Clutch Safety...18 Clutch System ...84-86 Clutch/Drive System Care/Storage . . 97 Clutching Chart...99 Cold Weather Drive-Away ...18 Controls and Linkage Care/Storage . 97 Coolant ...75 Cooling System...75 Customer Service ...106 F Fasteners, Hood and Side Panel ...48 Fluid Change, Chaincase ...71 Fluid Level Brake Fluid...81 Chaincase ...71 Oil Bottle ...57 Front Rear Scissor Stop ...38 Front Suspension Adjustments . . 32-33 Front To Rear Coupling ...38 FRSS ...38 Fuel ...55 Fuel Filter...
... Clutch Safety...18 Clutch System ...84-86 Clutch/Drive System Care/Storage . . 97 Clutching Chart...99 Cold Weather Drive-Away ...18 Controls and Linkage Care/Storage . 97 Coolant ...75 Cooling System...75 Customer Service ...106 F Fasteners, Hood and Side Panel ...48 Fluid Change, Chaincase ...71 Fluid Level Brake Fluid...81 Chaincase ...71 Oil Bottle ...57 Front Rear Scissor Stop ...38 Front Suspension Adjustments . . 32-33 Front To Rear Coupling ...38 FRSS ...38 Fuel ...55 Fuel Filter...
Owners Manual
Page 120
..., Warranty...107 Reverse Operation ...61-62 Reverse Warning ...22 Rider Capacity ...13 Rider Information Center...30-31 Riding Apparel ...11 Riding Position ...10 RRSS ...39 L Lights ...83 Headlight Replacement...83 Taillight/Brake Light ...83 Limiter Strap Position ...37 Low Oil Indicator Light...56 Low Oil Level ...57 Lubrication...70-71 Lubrication, Rear Suspension ...70 118 INDEX F Fuel Lines ...Fuel Premix (Initial Fill) ...Fuel Pump ...Fuel Recommendation ...Fuel System Deicers ...Fuel Valve ...Fuel Warnings ...75...
..., Warranty...107 Reverse Operation ...61-62 Reverse Warning ...22 Rider Capacity ...13 Rider Information Center...30-31 Riding Apparel ...11 Riding Position ...10 RRSS ...39 L Lights ...83 Headlight Replacement...83 Taillight/Brake Light ...83 Limiter Strap Position ...37 Low Oil Indicator Light...56 Low Oil Level ...57 Lubrication...70-71 Lubrication, Rear Suspension ...70 118 INDEX F Fuel Lines ...Fuel Premix (Initial Fill) ...Fuel Pump ...Fuel Recommendation ...Fuel System Deicers ...Fuel Valve ...Fuel Warnings ...75...
Owners Manual
Page 121
... Steering System Inspection...48 Stopping, Emergency ...51 Storage Procedures, Extended . . 96-97 Storage, Cargo ...26 Storage, Daily ...63 Survival Preparation ...12 Suspension Coupling ...38-39 Suspension Inspection, Pre-Ride ...44 Suspension Lubrication, Rear ...70 Suspension Performance Tips...35 Switches Engine Stop Switch ...59 Handlebar Grip Warmer Switch . 25 Headlight Dimmer Switch ...25 Ignition Switch ...25 Tether Switch ...49 Throttle Safety Switch ...59 T Tachometer ...31 Taillight/Brake light Replacement . . 83 Tether Switch ...49 Throttle Lever ...60 Throttle...
... Steering System Inspection...48 Stopping, Emergency ...51 Storage Procedures, Extended . . 96-97 Storage, Cargo ...26 Storage, Daily ...63 Survival Preparation ...12 Suspension Coupling ...38-39 Suspension Inspection, Pre-Ride ...44 Suspension Lubrication, Rear ...70 Suspension Performance Tips...35 Switches Engine Stop Switch ...59 Handlebar Grip Warmer Switch . 25 Headlight Dimmer Switch ...25 Ignition Switch ...25 Tether Switch ...49 Throttle Safety Switch ...59 T Tachometer ...31 Taillight/Brake light Replacement . . 83 Tether Switch ...49 Throttle Lever ...60 Throttle...