Polaris 500 IQ Shift Owner'S Manual Download

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100

TROUBLESHOOTING

Engine Troubleshooting

Problem

Probable Cause Solution

Noise in drive sys-

tem

Broken drive clutch

components

• SEE YOUR DEALER.

Bearing failure/

chaincase, jackshaft,

or front drive shaft

• SEE YOUR DEALER.

Drive belt surface

flat spots

• Inspect and replace as needed.

Drive chain loose

• Inspect and adjust (or replace).

Drive chain worn,

sprocket teeth bro-

ken

• SEE YOUR DEALER.

Poor low RPM per-

formance

Worn drive belt

• Inspect and replace as needed.

Excessive belt/

sheave clearance

• SEE YOUR DEALER.

Loose torque stop

• Inspect and adjust.

Sticky clutch

• SEE YOUR DEALER.

Engine doesn't turn

Seized engine

• SEE YOUR DEALER. Seizure is a

result of poor lubrication, inade-

quate fuel supply, broken parts or

improper cooling.

Hydrostatic lock

• Fuel may have entered the crankcase

while the vehicle was standing or

being transported. SEE YOUR

DEALER to correct the cause. Drain

plug(s) are located on the lower

crankcase for emergency draining.

Engine doesn't start

(electric start mod-

els)

Wire connections

• SEE YOUR DEALER.

Engine requires

more than normal

pulls to start

Poor fuel

• Replace with fresh winter fuel.

Not enough fuel get-

ting to engine

• SEE YOUR DEALER.

Summary of Contents for 500 IQ Shift

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Page 3: ...ns 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 th...

Page 4: ...velopment of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner...

Page 5: ...n and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publicati...

Page 6: ...of your snowmobile s controls and features The Perfect Fit 28 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 40 This secti...

Page 7: ...___________________________________ Key Number ___________________________________________________________ Important Notes for Owners and Drivers After reading this manual store it in the snowmobile f...

Page 8: ...rm to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound...

Page 9: ...rsonal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided...

Page 10: ...in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as d...

Page 11: ...n off the igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation WARNING Serious injury can occur if fingers or cloth...

Page 12: ...and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed b...

Page 13: ...equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means...

Page 14: ...r in inclement weather Always observe all laws governing snowmobile operation and speed limits Always be alert and pay attention to the trail ahead Multiplying speed MPH by 1 5 will equal the approxim...

Page 15: ...wn out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or high ways Steep embankments may also hide your view Always leave yourself a w...

Page 16: ...lope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in moun tain...

Page 17: ...erfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Driving on Slippery Surfaces WARNING Never attempt an...

Page 18: ...to help slow the machine and keep it from rolling freely downhill WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may res...

Page 19: ...balance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If...

Page 20: ...g may disrupt this pre cision balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure th...

Page 21: ...ive wear and damage to the slide rail track and or engine If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the thr...

Page 22: ...s yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spin...

Page 23: ...93 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min 5 min...

Page 24: ...als on the snowmobile If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number i...

Page 25: ...tunnel Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death No Passenger Warning The NO PASSENGER warning decal is on t...

Page 26: ...behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Machine stopped...

Page 27: ...d adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approved models only reduce speed...

Page 28: ...d 4 Handlebar 5 Seat 6 Taillights 7 Rear Bumper 8 Snow Flap 9 Console Storage Compartment if equipped 10 Suspension 11 Track 12 Skis 13 Nosepan 14 Front Bumper do not use for pulling or dragging the s...

Page 29: ...Headlight Adjuster 5 Speedometer 6 Engine Stop Switch 7 Choke Lever 8 Ignition Switch 9 Brake Lever 10 Parking Brake 11 Handlebar Grip Warmer Switch 12 Thumbwarmer Switch 13 Electronic Reverse Button...

Page 30: ...el valve off when ever the snowmobile is stored or parked 1 Turn the valve clockwise to turn off the fuel supply 2 Turn the valve counter clock wise to turn on the fuel supply Adjustable Headlights Ad...

Page 31: ...ns We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The machine should be methodically tested one change at a time under the same...

Page 32: ...one inch of pre load beyond the factory settings and ensure that both sides are adjusted the same When decreasing preload make sure at least two turns of preload are hold ing the spring between the r...

Page 33: ...nts involve a compromise or trade off For example a suspension set up for snowcross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bottom out harshly on...

Page 34: ...on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are available from your dealer Polaris offers track kits for improved flotati...

Page 35: ...ard on the seat and bounce up and down several times collapsing the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact location used for mea...

Page 36: ...rmer ride is desired See your dealer for more information Limiter Strap Position Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling If a rider pre...

Page 37: ...oupling and the Front Rear Scissor Stop FRSS This type of coupling is available as an accessory for your model The front rear scissor stop FRSS couples the movement of the front torque arm with the re...

Page 38: ...and the front torque arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performanc...

Page 39: ...st for most trail riding conditions To decrease weight transfer under acceleration for improved corner ing rotate the RRSS to a higher position To increase weight transfer or ski lift during accelerat...

Page 40: ...oducts on the skis and track must be maintained to obtain proper vehicle control on hard packed snow or ice See your dealer for assistance Accessories Polaris offers a wide range of accessories for yo...

Page 41: ...hicle when the handle bars are turned fully to the left or right Handlebar Position Follow these steps to adjust handlebar position 1 Remove the handlebar cover 2 Loosen the four upper and four lower...

Page 42: ...llow these steps to adjust handlebar angle at the handlebar block 1 Remove the handlebar cover 2 Loosen the four upper adjuster block bolts 3 Adjust the handlebar to the desired angle 4 Torque the bol...

Page 43: ...eering System 44 Recoil Rope 45 Cooling System Seal 73 Parking Brake Lock Brake Lever Brake System 42 43 77 Auxiliary Shut Off Switch Engine Stop Switch 46 Ignition Switch 46 Taillight Brakelight Head...

Page 44: ...perience n Throttle Lever The throttle and brake are the primary controls of your snowmobile Always make sure both are functioning properly Squeeze the throttle lever to make sure it compresses evenly...

Page 45: ...tes low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 79 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed che...

Page 46: ...y into place Do not force the lock or it may break The brake light will illuminate if the parking brake lever lock is set while the engine is running It will also illuminate when the service brake is...

Page 47: ...ich could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle Use of traction products such as studs increases the possibility of tr...

Page 48: ...mstances should your snowmobile be operated with the hood open or removed Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowm...

Page 49: ...ne Pull it up to allow restarting n Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF n Tether Switch if equipped If your machine has a tether switch remove the teth...

Page 50: ...not operate the electric starter or pull rope starter while the engine is running NOTICE Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Da...

Page 51: ...s Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle openings and machine speeds to reduce friction on all close fitting machined...

Page 52: ...e See page 98 for the part numbers of Polaris products Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage Oils may also be incomp...

Page 53: ...y or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up of the engine drive train and track 1 Use an appropriate stand to securely sup po...

Page 54: ...ng is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclo...

Page 55: ...fuels for your machine Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of...

Page 56: ...ld result in engine damage This is especially important when the machine is operated in mountainous ter rain NOTICE Operating the snowmobile without adequate engine lubrication can result in serious e...

Page 57: ...e performance A lean mixture may be caused by things like fuel line restrictions for eign matter in the carburetor or clogged fuel filters A rich mixture may be caused by snow build up on the pre filt...

Page 58: ...ain jet installed in production is not correct for all altitudes and or temperatures See page 74 for more information NOTICE A main jet that s too small will cause a lean operating condition and may c...

Page 59: ...e safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a carburetor throttle system malfunction immediately...

Page 60: ...throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 If the engine doesn t start take the snowmobile to an authorized Polaris dealer for service Ex...

Page 61: ...ter 45 sec onds in reverse This feature protects the engine from overheating and will reset when it is shifted into forward or when the engine is stopped and restarted WARNING Improper reverse operati...

Page 62: ...started Disengaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Push the yellow reverse button for one second and release The engine will slow and and begin to rotate forward The light...

Page 63: ...used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person ridi...

Page 64: ...is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If...

Page 65: ...rvals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty perio...

Page 66: ...C Clean R Replace L Lubricate Item See Page Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 82 I I I Drive Belt Condition 8...

Page 67: ...AGEMENT Pilot Air Screws I I I Carburetor synchronize 74 I I I Idle RPM I I I Throttle Lever 57 I I I I I Oil Pump Lever synchronize I I I Throttle Cable 67 L L L Choke Cable 67 L L L Choke 67 I I I V...

Page 68: ...nsion Shock Oil I I I I Cooling System 73 I I I I Drive Shaft Bearing 67 L L L I Jackshaft Bearings 96 L L L I Skags Wear Bars 93 I I I I I Ski Saddle Spindle Bolts I I I I I Steering Arm s I Drive Ch...

Page 69: ...n pivot shafts with Polaris Premium All Season Grease at 500 miles 800 km initially every 1000 miles 1600 km after that and before off season storage each year Lack of lubrication will adversely affec...

Page 70: ...re than four pumps Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as shown Choke and Choke Cable Lub...

Page 71: ...sight glass 2 Change the chaincase oil after the first 500 miles 800 km then every 1000 miles 1600 km or seasonally Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 98 for the...

Page 72: ...from the plug 4 Install a new sealing washer on the drain plug Tip The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 5 Reinstall the drain p...

Page 73: ...embly process Avoid prolonged idle speeds which cause plug fouling and carbonization Use recommended spark plugs with the proper gap Use only resistor type spark plugs Torque spark plugs to 18 22 ft l...

Page 74: ...arburetor throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrode...

Page 75: ...nomy or carburetor mal function Always reinstall the intake filters before operating the snowmobile Oil Lines Inspect oil line condition every 1000 miles 1600 km Oil Filter The oil filter is located a...

Page 76: ...kinked replace it promptly n Cooling System Inspect the fan intake and outlet edge seal at the input and output for cracks loosening of duct and blockage or obstructions Make any neces sary repairs pr...

Page 77: ...engine damage Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or...

Page 78: ...r Always work in a well ventilated area away from anything that may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the fuel warnings on page 51 Cleani...

Page 79: ...move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut 1 3 Finger tighten the adjuster bolt 2 until it...

Page 80: ...eath Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad mater...

Page 81: ...h a plastic sight glass in the brake reservoir If the fluid is sufficient the sight glass will be black If the sight glass is any color other than black add brake fluid Keep the master cylinder cover...

Page 82: ...2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16I 6 8 cm below the lip of the reservoir open ing Reinstall the gasket and cover 3 Slip a rubber tube over the ball of...

Page 83: ...from the housing 4 With the wire harness 2 attached to the bulb 3 with draw the bulb from the housing 5 Grasp the bulb by its metal base and carefully separate the bulb from the harness Headlight Bulb...

Page 84: ...lacement 1 Remove the screws securing the taillight lens Remove the lens 2 Push the bulb inward and turn it counterclockwise to remove it 3 Install a new bulb Push the bulb inward and turn it clockwis...

Page 85: ...by an autho rized Polaris dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty The bushings in the weights and rollers of Polaris clutches are m...

Page 86: ...Reinstall it before starting the snowmobile 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...

Page 87: ...ockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the L wrench and store it in the tool kit 4 Reinstall the side panel 5 Close and secure the hood Drive B...

Page 88: ...the clutch see page 83 Turn the wrench clockwise slightly to remove pressure from the sheaves 2 Loosen the 7 16I jam nut 3 Using a 1 8I Allen wrench turn the set screw inward clockwise to increase the...

Page 89: ...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 2 Rotate the track by hand to chec...

Page 90: ...er surfaces that have little or no snow for lubrication The slide rail needs snow for lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in l...

Page 91: ...tension and alignment Tip Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the machine and safely support it off the ground 3 Pl...

Page 92: ...e equal adjust ment on both sides of the track 8 Repeat the measurement on the other side of the track Tip Check more frequently when the machine is new 9 Start the machine and slowly rotate the track...

Page 93: ...Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track r...

Page 94: ...91 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary...

Page 95: ...dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measure...

Page 96: ...vehicle control may result causing serious injury or death Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their ori...

Page 97: ...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 n Check suspension mounting bol...

Page 98: ...g the useful life of many components See page 98 for the part numbers of Polaris products Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood chassis and plastic...

Page 99: ...and corrosion on precision engine parts during storage Whenever the machine is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instruction...

Page 100: ...sion Moderate track tension should be maintained during summer storage The machine should be supported off the ground to allow the track to hang freely Transporting the Snowmobile Whenever the snowmob...

Page 101: ...5 l Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 95 l 2872951 Synthetic Chaincase Lubricant 12 oz 355 ml Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 8...

Page 102: ...narrow Replace the drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for appli cation Replace the drive belt Clutch alignment out of spec Adjust alignment of...

Page 103: ...ve clearance SEE YOUR DEALER Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Engine doesn t turn Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fu...

Page 104: ...veral times may be necessary to change plug s Poor engine com pression Mixture is too lean A main jet that is too small will cause seizure result ing in loss of power This indicates a major engine pro...

Page 105: ...ck ski alignment see page 92 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Set static sag s...

Page 106: ...atures Check for snow ingestion Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break...

Page 107: ...ontained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the fol lowi...

Page 108: ...owner reports theft A In addition to notifying the proper law enforcement officials the owner must call Polaris Customer Service B Owners must provide their name address telephone number and the mode...

Page 109: ...not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has...

Page 110: ...present your copy of the Warranty Registration form to the dealer The cost of transpor tation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling deale...

Page 111: ...verage in the event of a warranty claim This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress he...

Page 112: ...overage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are requi...

Page 113: ...ake your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verific...

Page 114: ...omponents of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited...

Page 115: ...ue to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing compet...

Page 116: ...r 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 KM TECHNICIAN SERVICE PERFORMED...

Page 117: ...114 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 118: ...115 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 119: ...rive Away 17 Controls and Linkage 95 Coolant 73 Cooling System 73 Customer Service 104 D Disabled Operators 11 Drive Belt 17 84 Drive Belt Adjustment 85 Drive Belt Condition 83 Drive Belt Deflection 8...

Page 120: ...ear Rear Scissor Stop 35 Rear Suspension Adjustments 30 36 Rear To Front Coupling 35 Recoil Rope 45 Recommended Maintenance 7 Registration Warranty 106 Reverse 58 59 Reverse Warning 23 Rider Capacity...

Page 121: ...for Storage 97 Track Inspection 86 Track Lubrication 87 Track Maintenance 86 90 Track Safety 8 Track Tension 31 88 Track Warm Up 50 Track Warning 22 Traction Products 37 Transporting the Snowmobile 97...

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