Polaris 600 Dragon Switchback Owner'S Manual Download Page 92

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MAINTENANCE

Spark Plug Removal and Replacement

1. Remove the spark plug cap.
2. Using the special wrench provided in

the tool pouch, rotate the spark plug

counterclockwise to remove.

3. Reverse the procedure for spark plug

installation.

4. Torque to 18-22 ft. lbs. (24-30 Nm).
5. Reinstall the spark plug cap.

Oil Lines

Inspect oil line condition every 1000 miles (1600 km).

Oil Filter

The oil filter is located at the side of

the oil tank. Have your dealer change

the oil filter and bleed the system

annually or every 1000 miles (1600

km).

TIP:

The direction of the arrows indicates

the direction of flow through the fil-

ter.

Summary of Contents for 600 Dragon Switchback

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Page 3: ...ons 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 4: ...evelopment 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 s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Mas...

Page 5: ... ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2010 Owner s Man...

Page 6: ... of your snowmobile s controls and features The Perfect Fit 41 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 58 This section explains procedures that must be performed before riding Operation 65 This section explains proper engine break in operation of features and general operating procedures Maintenance 78 This section...

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Page 8: ... are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding clubs When teaching inexperienced operators to ride set up a predetermined course for practice Ma...

Page 9: ...that snowmobiles conform 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 of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter ...

Page 10: ... mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number ___________________________________________________ Tunnel VIN right side of tunnel __________________________________________ Engine Serial Number on recoil housing _____________________________________ Key Number ___________________________________________...

Page 11: ...ersonal 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 may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard...

Page 12: ... 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 directed Failure of critical machine components may result from opera tion with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aero...

Page 13: ...rn 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 clothing contact the moving parts of an engine Always stop the engine before attempting adjustments Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may...

Page 14: ...A 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 by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasse...

Page 15: ... you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival 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 of building a fire and a two way radio or cel lular telephone For added pro...

Page 16: ...re necessary for stopping 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 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 approximate number of feet per sec o...

Page 17: ...rown 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 way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Avoid travelling on frozen bodies of water When teaching inexperien...

Page 18: ...now is connected You may be riding on a flat slope 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 tainous terrain Before riding in mountainous terrain call or log on to your local ava lanche advisory to get current weather and snow stability information Fo...

Page 19: ...terfering 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 abrupt change of direction when operating on slippery surfaces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces steering and braking control which may result in loss of...

Page 20: ... 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 result in brake failure Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system This condition may lead to a sudden loss of brakes and or fire and may r...

Page 21: ...r 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 you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop ...

Page 22: ...ex mechanism that rotates at high speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion 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 the skis and track are loosened from ice and snow before attempting to drive Apply the throt...

Page 23: ...and lubrication will lead to overheating of the slide rail and track causing premature wear damage and failure which can result in serious injury Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating for prolonged periods on ice hard packed surfaces or roads Operating in Deep Snow If the machine becomes stuck...

Page 24: ...l as 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 spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide pro tection under normal riding conditions Your snowm...

Page 25: ... 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 Wind Speed in KPH Actual Thermometer Reading _C 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 Equivalent Temperature _C Calm 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 3 0 4 7 11 14 18 22...

Page 26: ... replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Clutch Cover Warning This warning decal is found under the hood on the clutch cover WARNING Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with plenum belt guard removed Never run engine with drive belt removed Never service c...

Page 27: ... 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 Snowmobiles designed for a single rider only have a NO PASSENGER warning decal WARNING This vehicle is designed for operator only NO PASSENGER One Passenger Warning Snowmobiles designed for an operator and one passenger have a ONE PASSENGER warning decal WAR...

Page 28: ...ing 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 and engine at idle push yellow button on LH con trol to reverse Flashing light on dash indicates reverse operation Push button again to return to forward Operation Warning The operation warning decal is also located on the consol...

Page 29: ...nd 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 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 ...

Page 30: ...features shown 8 13 5 6 7 12 11 2 1 3 4 10 9 1 Nosepan 2 Skis 3 Front Bumper do not use for pulling or dragging the snow mobile 4 Hood 5 Headlight 6 Windshield 7 Handlebar 8 Operator Seat 9 Taillight 10 Rear Bumper 11 Snow Flap 12 Suspension 13 Track ...

Page 31: ...auge 4 Engine Stop Switch 5 Throttle Control 6 Recoil Starter Handle 7 Hood Hold Down Straps 8 Parking Brake Lock 9 Handlebar Grip Warmer Switch 10 Thumbwarmer Switch 11 Electronic Reverse Button 12 Multi Function Display MFD Control 13 Headlight Dimmer Switch 14 Brake Lever 1 2 4 5 7 6 3 12 11 13 8 9 10 14 ...

Page 32: ...es DET activation is temporary and the timing will return to normal automatically In extreme conditions the DET sys tem retards timing and holds it in a retarded state If this occurs replace the fuel with recommended fuel or see your Polaris dealer for service Sensor Fail Safe The DET includes a sensor fail safe system to prevent the engine from damage if the sensor fails becomes disconnected or i...

Page 33: ...dicator 8 High Beam Indicator Item 1 RPM or Speed Altitude if equipped Service Interval 2 Electrical System Voltage Level 3 MAX Maximum MPH KPH or RPM MPH Miles per hour KPH Kilometers per hour RPM Engine crankshaft revolutions per minute 4 Air Temp if equipped Engine Temp Degrees Celsius Degrees Fahrenheit 5 Miles Kilometers 6 Hours Trip 1 Trip 2 Trip F Service Label Altitude Label 7 Fuel Level i...

Page 34: ...Speedometer Tachometer The speedometer and tachometer can be viewed in either the analog or the digital display If the analog display is set to show speedometer read ings the digital screen will automatically display the tachometer option 1 If the analog is set to show the tachometer the digital screen will show the speedometer option 2 To change preferences press and hold the MODE button for thre...

Page 35: ... engine RPM whichever set ting is selected regardless of the display program being viewed Performance Program The Performance Program automatically displays either speed or tachometer whichever is opposite the analog display See page 31 It also displays electrical system voltage and fuel level if equipped While in the Performance mode press the SET button to cycle through the odometer Trip 1 Trip ...

Page 36: ... F automati cally displays when the fuel level is low The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1 8th tank The Trip F odometer records distance traveled until enough fuel is added to raise the level above 1 4 tank The fuel symbol and the fuel bar will continue to blink until the fuel level is above 1 4 tank The Trip F odometer will automatically ...

Page 37: ...lashing press the SET switch once to advance one hour or press and hold the SET button to advance the hour once every 0 2 seconds 3 Press the MODE button to save the hour and flash the minutes 4 Set the minutes in the same manner 5 When finished press the MODE button to save the new setting If the MODE button is not pressed within ten seconds the clock will automatically save the new entry ...

Page 38: ...re will display as additional screens in the engine program Press the SET button to dis play the ambient air temperature and altitude screens Air Temperature if equipped The MFD displays actual air temperature Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement Hour Meter The hour meter records the total hours of engine operation since manufact...

Page 39: ... 50 feet 15 m or press and hold the button to advance 100 ft 30 m every 0 1 seconds Adjust the altitude display to within 50 ft 15 m of current altitude TIP The gauge reads barometric pressure and allows the rider to compensate for daily fluctuations in air pressure The gauge can adjust the displayed altitude to 1300 ft 396 m from the preset value It will adjust up to 1300 ft 396 m above the calib...

Page 40: ...f the History Program is not currently displayed The History Program will display the history of the Maximum Speed Maximum RPM and Service Interval settings Maximum Speed RPM Reset While in either the MAX MPH or the MAX RPM mode press and hold the SET button for three seconds to reset the recorded maxi mum values for both MPH and RPM Both of these values are reset at the same time Reset the MAX MP...

Page 41: ...terval 1 Enter the service interval screen 2 Press and hold the SET button for ten seconds continuing to hold even after the display begins to flash 3 When the display stops flashing release the button The service interval has been reset To reset the reminder at a new interval 1 Enter the service interval screen 2 Press and hold the SET button for five seconds until the hours begin to flash 3 Imme...

Page 42: ... compartment 4 Carefully cut the bottom of the com partment opposite the wires to separate the heat sealed seams Squeeze the corners of the compartment inward so the battery is visible TIP Note the orientation of the battery before removing it An incorrectly installed battery will not maintain the clock 5 Using needle nose pliers grasp the battery and rotate it so the lead ing edge of the battery ...

Page 43: ...evious cable tie was located Make sure the battery wires are not stretched tight Gauge Cleaning 1 Wipe the gauge face as needed using a clean cloth and a mild soap and water solution Wipe dry with clean soft cloth 2 Clean the back side of the gauge using a clean cloth and a mild soap and water solution Do not remove the electrical connectors or pro tective rubber boot Do not spray the back side of...

Page 44: ...ing 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 conditions trail and snow conditions vehicle speed riding position etc after each adjustment until the best ride is achieved IFS Components 1 Skis 2 Front shocks and springs 3 Rod ends 4 A arms IFS Adjustment Options Fron...

Page 45: ...d 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 retainer on the top of the shock and the threaded spring preload adjuster nut on the shock body Failure to do so could cause the retainer to fall off when the suspension is fully extended TIP Not all ...

Page 46: ...e Turn the adjuster to the right for a softer ride Shock Valving Some shocks can be revalved if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness Please see your Polaris dealer WARNING Changing shock valving requires special tools and a sound knowledge of mechanical theory tool use and shop procedures to perform the work safely and correctly Sh...

Page 47: ...ents 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 bot tom out harshly on a snowcross course Refer to the suspension setup label on your snowmobile or see your Polaris dealer for initial suspension setup information Additional adjustments can be made after initial setup ...

Page 48: ...g 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 flotation in deep snow See your dealer for assistance Keep the suspension pivot points lubricated This will reduce mois ture and rust build up and ensure proper function of the suspension components Grease...

Page 49: ...st measurement with no rider and with the rear suspension at full extension The rear bumper may need to be lifted upward slightly to fully extend the rear sus pension Next have the rider drop down hard 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 measu...

Page 50: ...X Y If the measured sag is incorrect adjust the FRA position and or rear torsion spring preload TIP This is only an initial setup and final spring preload may vary based on rider preference and riding conditions Suspension Recommended Sag Adjustment See Page IQ 121 4 5 inches 10 13 cm Torsion Spring Preload 48 SwitchBack LX 136 4 5 inches 10 13 cm Torsion Spring Preload 48 ...

Page 51: ...osition 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 Different rate torsion springs are available if a firmer ride is desired See your dealer for more information Soft Medium Firm ...

Page 52: ...e ski pressure for improved steering performance adjustments can be made to the front limiter straps Tighten the straps to increase ski pressure Loosen the straps to reduce ski pressure Some models have only one lim iter strap 1 Remove the nuts and flat washers from the upper limiter straps 2 Relocate the straps to the desired position 3 Reinstall the nuts and washers Tighten securely Upper Nuts ...

Page 53: ...uster on the shock reservoir to make adjustments to the compression damping Positions are labeled on the shock When adjusting we recommend that you turn the adjuster one click then test ride Turn the adjuster clockwise for a stiffer ride Turn the adjuster counterclockwise for a softer ride Stiffer Softer ...

Page 54: ...pension coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amount of indepen dence between the movement of the front torque arm and the rear torque arm When hitting a bump the front torque arm starts to compress The FRSS links that movement to the rear torque arm ...

Page 55: ...ont 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 performance An adjustment dot is located on the RRSS This dot is on the longest end of the scissor stop Rear Rear Scissor Stop RRSS Attributes Moving the RRSS to a higher position will have the following effects on the s...

Page 56: ...or 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 acceleration rotate the RRSS to a lower position TIP Your dealer can help you with ini tial setup and additional setup instructions to help you achieve your optimum ride A scissor stop tool is also available from ...

Page 57: ...t the handlebar forward or rearward to the desired position 3 Tighten the bolts Handlebar Angle 1 Loosen the four bolts on the top of the adjuster block If necessary pry the blocks apart with a screwdriver 2 Adjust the handlebar forward or rearward to the desired angle 3 Tighten the bolts Loosen top bolts to adjust handlebar angle Loosen bottom bolts to adjust handlebar position ...

Page 58: ...snowmobile Use of unapproved parts and accessories may result in Non compliance with government industry requirements Voiding of warranty Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service ...

Page 59: ...f clearance between upper carrier wheels and track Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tunnel Track studding will enhance braking control on hard packed snow or ice but extreme caution is still required on such surfaces Steering abil ity may be reduced on hard packed snow or ice When studded t...

Page 60: ...roper vehicle control Maintain a proper balance between the number of studs and the length of carbide on the skags the more studs you use the longer the carbide on the skags should be See your dealer s track studding chart Wear Strips To avoid excessive tunnel wear tunnel wear strips must be installed whenever track studding is used Wear strips are designed for a specific stud length See your deal...

Page 61: ... System 62 Recoil Rope 63 Coolant Level 91 Parking Brake Lock Brake Lever Brake System 60 61 96 Auxiliary Shut Off Switch Engine Stop Switch 64 Ignition Switch 64 Taillight Brakelight Headlight 64 Suspension Mounting Bolts 114 Skags Wear Bars 113 Ski Saddle and Spindle Bolts 114 Hood Straps Latches 63 Seat Latches if equipped 63 Throttle Lever Safety Switch 72 73 Rear Wheel Idler Bolts 109 Tether ...

Page 62: ...l Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience 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 and smoothly When released the lever should immediately return to the idle pos...

Page 63: ...ates low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 98 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 97 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always ...

Page 64: ...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 in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly Th...

Page 65: ...he snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle WARNING Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could seve...

Page 66: ...ways ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmo bile n Seat Latches If your snowmobile is equipped with a removable seat ensure that the seat latches are securely in place before every use of the snowmobile n Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside...

Page 67: ...switch down to stop the engine 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 tether from the switch to make sure the engine stops immediately n Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before oper...

Page 68: ...o snap back into the housing Damage may result 5 If the engine does not start after several attempts slightly depress the throttle no more than 1 4I open while cranking the engine When the engine starts immediately release the throttle CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running Restarting an Engine If the rider ...

Page 69: ...hree hours of operation will damage close fitted engine parts 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 parts allowing them to break in slowly without damage Use of any lubricants other than those recommended by Polaris may cause serious engin...

Page 70: ...ic 2 cycle oil for this engine See page 118 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 incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All Polaris oils are compatible with each other Slide Rail and Track C...

Page 71: ...ry 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 port the rear of the snowmobile at the rear bumper The track should be about 4I 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and ...

Page 72: ...ous and can cause loss of consciousness or death in a short time The engine exhaust from this product contains chemicals known to cause can cer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 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 ga...

Page 73: ... fuel is used after setting up the vehicle for non ethanol fuel use Depending on your model always reinstall the ethanol fuel resistor or disconnect the mode change wires before operating with ethanol fuel When in doubt about fuel quality always use the ethanol fuel resistor or unplug the wires Fuel Resistor 600 Models On 600 cc models the factory installed fuel resistor is for the use of ethanol ...

Page 74: ...uld 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 engine damage Always check the oil level when refu eling Add oil as needed Always maintain a visible level of oil in the tank If oil is not visible continued operation may cause serious engine damage ...

Page 75: ...le 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 push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer Test the throttle safety switch system daily before operation 1 Sit on the seat...

Page 76: ...4 If the 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 Excessive freeplay in the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the machine to an authorized Polaris dealer for service...

Page 77: ...y See page 72 for more information about the engine stop switch and throttle safety switch SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch Interrupts ignition circuit Throttle Safety Switch Interrupts ignition circuit Tether Switch Option Interrupts ignition circuit ...

Page 78: ... to the chaincase or trans mission if shifting is attempted when the engine is operating above idle speed Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle Look behind the vehicle before and while backing Avoid sharp turns Apply throttle slowly Electronic reverse will activate only if the engine RPM is below 4000 WARNING ...

Page 79: ...transmission is in reverse The maximum engine RPM will be 6000 when in reverse TIP If the engine stops running the snowmobile will be in forward gear when it s restarted 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 starte...

Page 80: ... of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be 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 riding in the towed object Braking distances increase when towing loads Slow down ...

Page 81: ... 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 your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups ar...

Page 82: ...ervals 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 period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to...

Page 83: ... mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 101 I I I Drive Belt Condition 102 I I I I Clutches 101 C C C Belt Tension I I I I Clutch Sheaves 101 I I I I ENGINE COOLING Engine Mounts I I I I Recoil Rope I I I I Engine Torque Stop 105 I I I I Cylinder Head Bolts I I I Cylinder Base Nuts I I I I Ignition Timing BTDC I I I VES System...

Page 84: ...61 I I I I Brake System 60 96 I Brake Fluid 97 R FUEL MANAGEMENT Idle RPM I I I Throttle Lever 73 I I I I I Oil Pump Lever synchronize I I I Throttle Cable 84 L L L Throttle Position Sensor I I I Fuel Lines 90 I I I I I Fuel Filter 90 R R Oil Filter 89 R R Oil Lines 89 I I I Air Box I I I I I ELECTRICAL Auxiliary Shut Off Switch 64 I I I I I Throttle Safety Switch 72 I I I I I Ignition Switch I I ...

Page 85: ...il I I I I Cooling Fins and Shroud I I I I Drive Shaft Bearing 84 L L L I Jackshaft Bearings 116 L L L I Skags Wear Bars 113 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 95 I I I I I Hood Latches 63 I I I I I Rear Wheel Idler Bolts 109 I I I I I Idler Bolt Jam Nut 109 I I I I I Rear Suspension Pivot Shafts 83 L L L Steering Post U Joint 83 L L L Camber Alignment I I I Handlebar...

Page 86: ...easonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the life of the sus pension For more information about suspension lubrication and adjust ments see your Polaris dealer IQ 121 Switchback 136 LX 136 Rear Suspension IQ 121 Shown The Dragon Premium rear sus pension has no grease points it does not requi...

Page 87: ...or housing until grease purges from the seal on the inside of the tunnel This should take approximately two pumps Do not use more 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 ...

Page 88: ...e 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 118 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level sur face 2 View the oil level at the sight glass 3 Remove the fill plug 3 and add the recommended oil as needed Do not ov...

Page 89: ...ngs from the plug 4 Install a new sealing washer on the drain plug 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 plug Torque to 6 10 ft lbs 8 13 Nm 6 Remove the fill plug Clean off all metal shavings from the plug 7 Add 11 oz 325 ml of the recommended oil Do not overfill 8 Reinstall the fill plug making sure it is...

Page 90: ... plugs every 2000 2500 miles 3200 4000 km Use recommended spark plugs with the proper gap Use only resistor type spark plugs Torque spark plugs to 18 22 ft lbs 24 30 Nm Always carry spare spark plugs NOTICE Using non recommended spark plugs can result in serious engine damage A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe...

Page 91: ...nsulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service TIP The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetor throttle body adjustments Wet Fouled The wet fouled insulator ti...

Page 92: ...re for spark plug installation 4 Torque to 18 22 ft lbs 24 30 Nm 5 Reinstall the spark plug cap Oil Lines Inspect oil line condition every 1000 miles 1600 km Oil Filter The oil filter is located at the side of the oil tank Have your dealer change the oil filter and bleed the system annually or every 1000 miles 1600 km TIP The direction of the arrows indicates the direction of flow through the fil ...

Page 93: ... All fuel pump service must be performed by an authorized Polaris dealer Do not attempt to service the fuel pump Fuel Filter Fuel Lines See your Polaris dealer for replacement of the fuel filter every 1000 miles or annually Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal dete rioration from weather and fuel comp...

Page 94: ...d a 60 antifreeze 40 water mixture See page 118 for Polaris products Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system n Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are Coolant bottle or overflow tank Engine filler neck Pressure cap Connecting hose...

Page 95: ...ive slowly and stop frequently to allow the engine to cool down Driving in deep snow will also help cool the engine See your dealer for service Add coolant if the level is low Engine performance will be reduced if you continue operating when the high temperature light is on Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine drain the system completel...

Page 96: ...ghtly if necessary 2 Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark 3 Remove the bleed screw from the water outlet manifold and or the thermostat housing Allow the coolant to bleed through the system until it runs out the bleed holes Reinstall the bleed screw into the manifold 4 Add coolant to the coolant bottle to the maximum mark 5 Start the e...

Page 97: ...letely before inspecting CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running 1 Open the hood and inspect the muffler and pipes for cracks or dam age 2 Check for weak or missing retaining springs or damper support grommets 3 Check for loose clamps on the pipe covers ...

Page 98: ... 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 can no longer be adjusted by hand then back off 1 4 turn 4 Tighten the jam nut while holding the adjuster bolt Torque to 21 ft lbs 28 Nm 5 Release the brake lever lock 1 1 2 ...

Page 99: ...r death 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 material becomes thinner than the backing plate approximately 1 16I Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thickness is less than 1 16I 1 5 mm Excessive Lever Tr...

Page 100: ...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 free of dirt and debris The vent slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function Replace brake fluid...

Page 101: ...t 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 the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve...

Page 102: ... from the housing 4 With the wire harness 2 attached to the bulb 3 with draw the bulb from the hous ing 5 Grasp the bulb by its metal base and carefully separate the bulb from the harness Headlight Bulb Installation 1 Hold the bulb by its metal base and install it into the wire harness TIP Recommended replacement bulbs include H4 HB2 and 9003 bulbs 2 Insert the bulb into the housing 3 Connect the ...

Page 103: ...eplacement 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 clockwise to secure it 4 Reinstall the taillight lens ...

Page 104: ...by an authorized 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 lubricate clutch bushings Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum perfor mance See your dea...

Page 105: ...cracks and excessive looseness Replace the belt if any of these conditions exist See Drive Belt Troubleshooting on page 123 Always carry a spare drive belt for emergency use Store the spare belt on top of the electrical box which is mounted to the clutch cover For improved drive away during extremely cold tem peratures remove the belt and warm it to room tem perature Reinstall it before starting t...

Page 106: ...I 3 2 cm Drive Belt Adjustment 1 Install the L wrench into the open threaded hole in the outer sheave of the clutch see page 104 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 distance between the sheaves or outward counter clockwise to decrease the distance 4 Tighten ...

Page 107: ... 2 Turn the ignition key off Wait for the engine to come to a complete stop 3 Lock the parking brake 4 Open the hood and remove the left side panel 5 Rotate the driven clutch counterclockwise 1 4 turn by hand to ensure forward engagement 6 Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheav...

Page 108: ...eparate the sheaves as outlined in the belt removal procedures 3 Rotate the L wrench counterclockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 4 Remove the L wrench and store it in the tool kit 5 Reinstall the side panel 6 Close and secure the hood Torque Stop Periodically check torque stop clearance With clutches in proper alignment the torque stop clearance ...

Page 109: ... rinse with clean warm water For stubborn stains such as grease or oil use a citrus based cleaner 3M Citrus Base Cleaner recommended Spray onto the area to be cleaned and rub with a soft sponge Allow to sit for a couple of minutes and wash away with clean warm water Repeat as necessary to clean the surface NOTICE Never use a polishing buffing wax or any sponge that has an abrasive surface These pr...

Page 110: ...ting with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication The slide rail needs snow for lubrication Excessive wear indicates insufficient lubrication A...

Page 111: ...t 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 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel 4 Measure at the point where the weight is hanging TRACK TENSION DATA CHART Sus...

Page 112: ...de equal adjust ment on both sides of the track 9 Repeat the measurement on the other side of the track TIP Check more frequently when the machine is new 10 Start the machine and slowly rotate the track at least five revolu tions Let the track come to a stop do not apply brakes 11 Check track alignment see page 110 and adjust as necessary 12 Tighten the locknuts 13 Tighten the idler shaft bolts 14...

Page 113: ...ns 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 runs to the left loosen the idler shaft bolts then loosen the left locknut and tighten the left adjusting bolt If the track runs to the right loosen the idler shaft bolts then loosen the right locknu...

Page 114: ...111 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary ...

Page 115: ... 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 measurement between the skis at point X should be 1 8I to 1 4I 3 6 mm greater than the measurement at point Y TIP If the skis are misaligned we recommend that your dealer correct the align ment since camber...

Page 116: ...ed snow or ice Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter TIP Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement Some models are equipped with single skags Some models are equipped with dual skags 1 Raise and support the front of the machine so th...

Page 117: ...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 bolts for tightness n Check rear idler wheel bolts for tightness See page 109 n Check rear idler adjusting bolt locknuts for tightness n Check front torque arm limiter strap condition n Check rail slide condit...

Page 118: ...remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint The machine should be stored in a dry garage or shed out of direct sun light and covered with a fabric snowmobile cover Plastic tarp may cause con...

Page 119: ...gine Protection Proper preparation of the engine and fuel system is vital to the preven tion of rust 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 instructions provided on the container Always add Premium Carbon Clean or a fuel conditioner stabilizer to the...

Page 120: ...t parts Transporting the Snowmobile Whenever the snowmobile is transported 1 Be sure the fuel cap and oil cap are installed correctly 2 Tie the snowmobile to the transporting unit securely using suitable straps 3 Remove the ignition key to prevent loss Track and Suspension Moderate track tension should be main tained during summer storage The machine should be supported off the ground to allow the...

Page 121: ...haincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871329 Dielectric Grease Nyogelt Coolant 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt Additi...

Page 122: ... 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 SEE YOUR DEALER Engine mount bro ken or loose Inspect and replace SEE YOUR DEALER Machine fails to move Clutch jammed Check for twisted belt or broken spring SEE YOUR DEALER Track jammed Foreign object may be caught or the rail slide melt...

Page 123: ...ow 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 Poor fuel quality Use 87 91 octane fuel or higher 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 ...

Page 124: ...oblem that must be repaired before operating SEE YOUR DEALER Engine lacks power Fouled or defective spark plug s Replace the plug s Fuel filter loss of high RPM power SEE YOUR DEALER Incorrect clutching SEE YOUR DEALER Engine continually backfires Faulty plug s Change plug s Fuel System Dirt or ice may be in the fuel system deicer should be added to non etha nol fuel at all times for assurance aga...

Page 125: ...ing Set static sag see page 46 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Adjust limiter straps see page 49 Machine darts from side to side Check ski alignment see page 112 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 see page 46 ...

Page 126: ...ratures 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 machine loose from the snow Poor engine performance Check for carburetor and choke synchronization fouled plugs debris in the carburetor s and water ice or dirt in the fuel tank or fuel line Loading ...

Page 127: ...on tained in this manual Your dealer is also familiar with Polaris policies and pro cedures and will be happy to assist you When contacting us about parts service or warranty always provide the fol lowing information 1 Serial number 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experienced 6 Length of time and conditions of operation 7 Previous correspondence Use the page pr...

Page 128: ...e 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 num ber and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notify...

Page 129: ... 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 been structurally altered neglected improperly maintained used for racing or used for pur poses other than for which it was manufactured The warranty does not cover any dam ages that occur during tr...

Page 130: ...st present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility Polaris recommends that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at Polari...

Page 131: ...overage 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 heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamina...

Page 132: ...Coverage 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 required to validate this warranty A partial list of items excluded from coverage includes Damage due to accident fire explosion theft or other causes beyond Polaris control Damage caused by the failure o...

Page 133: ...take 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 verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of t...

Page 134: ...components 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 warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the followin...

Page 135: ...due 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 competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for perform...

Page 136: ...er 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 COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km ...

Page 137: ...134 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 138: ...135 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 139: ... 93 Cooling System Flushing 92 Customer Service 124 D DET 29 Detonation Elimination Technology 29 Digital Display 30 Disabled Operators 12 Drive Belt 19 Drive Belt Adjustment 103 Drive Belt Condition 102 Drive Belt Deflection 103 Drive Belt Installation 105 Drive Belt Removal 104 Drive Chain Tension 95 Driver Awareness 14 Driveshaft Bearing 84 Driving Downhill 17 Driving in Hilly Terrain 18 Drivin...

Page 140: ...D Components 30 MFD Digital Display Programs 32 38 MFD Settings 31 N Noise 6 O Oil Filter 89 Oil Indicator Light 71 Oil Injection System 67 Oil Level 71 Oil Lines 89 Oil Recommendations 67 Operating in Deep Snow 20 Operation Warning 25 26 Operator Safety 8 22 P Parking Brake Lever Lock 61 Passenger Warnings 24 Preload IFS Shock Spring 42 Pre Ride Checklist 58 Pre Ride Suspension Inspection 114 Pre...

Page 141: ...n Inspection Pre Ride 114 Suspension Maintenance 114 Suspension Performance Tips 45 Suspension Rear Lubrication 83 T Taillight Brakelight Replacement 100 Throttle Cable 84 Throttle Lever 59 73 Throttle Safety Switch 59 72 Torque Stop 105 Torsion Spring Preload IQ 48 Towing 77 Track 62 Track Alignment 110 Track Care for Storage 117 Track Inspection 107 Track Lubrication 107 Track Maintenance 107 11...

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Polaris 600 Dragon Switchback, Owner'S Manual

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