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POLARIS SNOWMOBILE

CENTRE D'AIDE

2020-03-23
Customizing Your Handlebar Alignments

To make the correct handlebar adjustment for your Polaris snowmobile, consult one of the three sections below that corresponds to your model. For more information, see your Owner’s Manual

RUSH, SWITCHBACK, XC and TITAN MODELS

The following information applies to

  • RUSH Pro-S and XCR
  • Switchback Assault, Adventure, SP, Pro-S and XCR
  • 600, 800 and 850 INDY Adventure, SP, XC, XCR and XD
  • TITAN SP, XC and Adventure
  • SKS 146
  • RMK 144
  • 600 Voyageur

Handlebar Component Fastener Torques
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 without first loosening its mounting screws/set screws. Take care to avoid damaging hand warmer/brake switch wires when moving components. 

handlebar component fasteners

Item Description Torque DO NOT
OVER-TIGHTEN
1  Left Handlebar Control Block   20 in-lbs (2.3 Nm)
2  Brake Lever / Master Cylinder 
 Torque the front screw first, then torque
 the screw next to the reservoir.
 70 in-lbs (7.9 Nm)
3  Upper / Lower Riser Clamps  14.8 ft-lbs (20 Nm) 
4  Throttle Lever Block Set Screw   27 in-lbs (3.1 Nm)
5  Throttle Lever Block Cover Screws   6 in-lbs (0.7 Nm)
6  Auxiliary Engine Stop Switch Set Screw   12 in-lbs (1.4 Nm)
7  Riser  Install with the "FWD"
 stamp facing toward
 the hood.
Not
 Shown 
 Hand Guard Mounts (if applicable)  Hand-Tight
Not
Shown
 Mountain Hoop Bar (if applicable)  10 ft-lbs (13.6 Nm)

Handlebar Angle

Handlebar angle

1. Loosen the four bolts on the top riser block (1).

2. Adjust the handlebar upward or downward to the desired 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, loosen the set screws for the left and right controls, rotate the controls slightly and then tighten the set screws to the proper torque. Do not stretch wires while adjusting the controls. Stretching the wires could damage the handwarmers.

3. Tighten the bolts. Torque to 14.8 ft-lbs (20 Nm).

Riser Angle

Riser angle

1. Loosen the four bolts on the bottom of the adjuster block (2). If necessary, pry the blocks apart with a screwdriver.

2. Adjust the riser forward or rearward to the desired position.

3. Tighten the bolts. Torque to 14.8 ft-lbs (20 Nm).

Riser Height (If Equipped)

Riser height

1. Release the riser clamp (1).

2. Adjust the handlebar upward or downward to the desired height.

3. Secure the riser clamp (1).

Periodically inspect the torque of the upper/lower handlebar clamp fasteners and slide fasteners.

 Item  Torque 
 Handlebar Clamp Fastener   16 ft-lbs (21 Nm) 
 ROX Slide Fastener  16 ft-lbs (21 Nm)
 Adjuster Cranks  Hand-Tight

Left Hand Control Alignment

Important: Moving the left hand control without loosening the four mounting screws will cause the housing locating pins to cut grooves into the handlebar. When this occurs, the left hand control may not clamp tightly to the handlebar. If the left hand control was inadvertently moved without loosening the screws and is loose, loosen the mounting screws and move the control block slightly to the left or right to relocate the pins. Torque the screws to specification. 

Left hand control

1. Loosen the brake master cylinder (A) mounting screws and move it away from the left hand control (B). Take care to avoid damaging hand warmer/brake switch wires when moving components.

2. Loosen the four left hand control mounting screws.

3. Move the control block to the desired position.

4. Tighten the screws to specification in the sequence shown in the image above. Do not over-torque. Torque to either 24 in-lbs (2.7 Nm) or 20 in-lbs (2.3 Nm), depending on your model. See your Owner’s Manual for the proper specification.

5. Return the master cylinder to its specified position. Make sure the clamp will not pinch the brake light signal wire. Torque the clamp screws to specification, which is 70 in-lbs (7.9 Nm), beginning with the front screw first and then the screw next to the reservoir. Do not over-torque.

Handlebar Component Locations

Refer to the following illustrations and measurements to position handlebar components at factory-specified locations. Notice: Do not move handlebar components without first loosening the components' screws.

For Switchback Assault, SKS, RMK, Voyageur, RUSH XCR and INDY models:

 Item  Measurement 
1 0.011 in (3 mm)
2 6.65 in (169 mm)
3 6.7 in (170 mm)
4 10 in (254 mm)
5 0.47 in (12 mm)
6 0.08 in (2 mm)

For TITAN, Switchback Pro-S, Switchback XCR and RUSH Pro-S models:

factory specifications

Item Measurement
1 0.039 in (1 mm)
2 0.51 in (13 mm)
3 10 in (254 mm)
4 0.13 in (3.3 mm)
5 0.08 in (2 mm)
6 6.65 in (169 mm)

Throttle Block Alignment

Throttle block

1. Slightly loosen the set screw (1) on the bottom of the housing.

2. Move the control block to the desired position.

3. Torque the screw to specification, which is 27 in-lbs (3 Nm). Do not over-torque.

Engine Stop Switch Alignment

Caution: The stop switch must be positioned in an easily accessible location. 

Engine stop

1. Slightly loosen the set screw on the bottom of the housing (1).

2. Move the switch to the desired position.

3. Torque the screw to specification, which is 12 in-lbs (1.4 Nm). Do not over-torque.

PRO-RMK MODELS

The following information applies to

  • PRO-RMK
  • SKS 155
  • RMK Assault
  • RMK KHAOS

Handlebar Component Fastener Torques

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 without first loosening its mounting screws/set screws. Take care to avoid damaging hand warmer/brake switch wires when moving components.

handlebar components

 Item   Description   Torque DO NO OVER-TIGHTEN 
1  Brake Lever / 
 Master Cylinder 
 60-80 in-lbs (6.7-9 Nm)
2  Auxiliary Engine Stop 
 Switch Set Screw
 12 in-lbs (1.4 Nm)
3  Handlebar Hook Screw   Aluminum: 10 ft-lbs (13.5 Nm)
 Steel: 18 ft-lbs (24 Nm)
4  Throttle Lever Block
 Set Screw
 27 in-lbs (3 Nm)
5  Throttle Lever Block
 Cover Screws
 6 in-lbs (0.7 Nm)
6  Handlebar Clamp 
 Screws/Bolts
 35 in-lbs (4 Nm)
7  PERC Button Screw  35 in-lbs (4 Nm)

Cyclone Brake Master Cylinder Alignment

Master cylinder

1. Loosen the two mounting screws. Take care to avoid damaging hand warmer/brake switch wires when moving components.

2. Move the master cylinder to the desired position.

3. Torque the screws to specification, which is 60-80 in-lbs (6.7-9 Nm). Torque the front screw (1) first and then torque the screw (2) next to the reservoir. Do not over-torque.

Throttle Block Alignment
Take care to avoid damaging hand warmer wires when moving components.

Throttle block

1. Slightly loosen the set screw (1) on the bottom of the housing.

2. Move the control block to the desired position.

3. Torque the screw to specification, which is 27 in-lbs (3 Nm). Do not over-torque.

4. With the engine off, test throttle lever movement after tightening the screw.

PERC Button Alignment

Perc

1. Loosen the mounting screw (1).

2. Move the PERC button to the desired position.

3. Torque the screw to specification, which is 35 in-lbs (4 Nm). Do not over-torque.

Engine Stop Switch Alignment

Engine stop

1. Slightly loosen the set screw (1) on the bottom of the housing.

2. Move the switch to the desired position.

3. Torque the screw to specification, which is 12 in-lbs (1.4 Nm). Do not over-torque.

Caution: The stop switch must be positioned in an easily accessible location.

Handlebar Hook Alignment

handlebar hook alignment

1. Slightly loosen the clamping screw (1). Do not remove the screw.

2. Rotate the hook to the desired position.

3. Torque the screw to specification. Do not over-torque. Torque aluminum bars to 10 ft-lbs (13.5 Nm) and steel bars to 18 ft-lbs (24 Nm). 

Handlebar Angle Adjustment

Handlebar angle

1. Securing the handlebar clamp bolts with an Allen wrench, loosen each of the four nuts. Take care to avoid damaging hand warmer/brake switch wires when moving components.

2. Adjust the handlebar forward or rearward to the desired angle.

3. 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 and right hand controls.

4. Tighten the handlebar clamp nuts. Torque to 35 in-lbs (4 Nm). Do not over-torque.

INDY MODELS
The following information applies to

  • 550 INDY 121, 144, LXT and Adventure
  • 550 Voyageur
  • 600 INDY
  • INDY EVO and INDY EVO RMK
  • WIDETRAK LX

To find handlebar component fastener torques for your vehicle, consult your Owner’s Manual. Note that 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 without first loosening its mounting screws/set screws. Take care to avoid damaging hand warmer/brake switch wires when moving components.

Left Hand Control Alignment

Left hand control

1. Loosen the four control block mounting screws.

2. Move the control block to the desired position. If the control is loose and was inadvertently moved without loosening the screws, move the control block slightly to the left or right to relocated the pins.

3. Tighten the screws to specification in the sequence shown in the image above. Torque to 24 in-lbs (2.7 Nm). Do not over-torque.

Throttle Block Alignment

Throttle block

1. Slightly loosen the set screw (1) on the bottom of the housing.

2. Move the control block to the desired position.

3. Tighten the screw to specification. Do not over-torque. Torque to the specification in your Owner’s Manual, either 35 in-lbs (4 Nm) or 27 in-lbs (3 Nm), depending on your model.

4. With the engine off, test throttle lever movement after tightening the screw.

Engine Stop Switch Alignment (600 INDY)

1. Slightly loosen the set screw on the bottom of the housing.

2. Move the switch to the desired position. The stop switch must be positioned in an easily accessible location.

3. Torque the screw to specification, 12 in-lbs (1.4 Nm). Do not over-torque.

Handlebar Angle or Position

Handlebar angle

1. Securing the handlebar clamp bolts (1) with an Allen wrench, loosen each of the four nuts (located on each bolt’s opposite end). Take care to avoid damaging hand warmer/brake switch wires when moving components.

2. Adjust the handlebar forward or rearward to the desired angle.

3. 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 and right hand controls.

4. Tighten the handlebar clamp nuts to the specification in your Owner’s Manual. This will vary based on model. Do not over-torque.

For more information, see your authorized Polaris Dealer. To find a dealer near you, use the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.

Mots-clés handlebar , adjustment , customize , setup