Polaris 600 IQ 2008 Owner'S Manual Download Page 152

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149

INDEX

Accessories . . . . . . . . . . . . . . . . . . . . 65

Adjustable Headlights. . . . . . . . . . . . 31

Adjustable Steering System . . . . 29-30

Air Pollution . . . . . . . . . . . . . . . . . . . . 6

Avalanches . . . . . . . . . . . . . . . . . . . . 15

Backrest (Touring) . . . . . . . . . . . . . . 32

Bearings . . . . . . . . . . . . . . . . . . . . . 128

Brake Components . . . . . . . . . . . . . 108

Brake Fluid . . . . . . . . . . . . . . . . . . . 109

Brake Inspection . . . . . . . . . . . . . . . 108

Brake Lever Travel . . . . . . . . . . 70, 108

Brake System Bleeding. . . . . . . . . . 110

Brakelight Replacement . . . . . . . . . 112

Brakes . . . . . . . . . . . . . . . . 70, 108-110

Carbide Skags . . . . . . . . . . . . . . . . . . 67

Cargo Area . . . . . . . . . . . . . . . . . . . . 31

Cargo Bag (Touring). . . . . . . . . . . . . 31

Chaincase Oil . . . . . . . . . . . . . . . 97-98

Choke . . . . . . . . . . . . . . . . . . . . . . . . 97

Cleaning and Preservation . . . . . . . 127

Clutch Alignment Offset. . . . . . . . . 113

Clutch and Drive System . . . . . . . . 128

Clutch Center Distance . . . . . . . . . . 113

Clutch Cover Warning . . . . . . . . . . . 23

Clutch Safety. . . . . . . . . . . . . . . . . . . 19

Clutch System . . . . . . . . . . . . . 113-117

Cold Weather Drive-Away . . . . . . . . 19

Compression Damping . . . . . . . . . . . 54

Controls and Linkage . . . . . . . . . . . 127

Coolant . . . . . . . . . . . . . . . . . . . . . . 103

Coolant Level . . . . . . . . . . . . . . . . . 103

Cooling System. . . . . . . . . . . . 103-105

Cooling System, Bleeding . . . . . . . 105

Cooling System, Flushing. . . . . . . . 104

Customer Service . . . . . . . . . . . . . . 137

DET. . . . . . . . . . . . . . . . . . . . . . . . . . 33

Detonation Elimination Technology. 33

Digital Display . . . . . . . . . . . . . . . . . 34

Disabled Operators . . . . . . . . . . . . . . 12

Drive Belt. . . . . . . . . . . . . 19, 114-117

Adjustment . . . . . . . . . . . . . . . 115

Condition . . . . . . . . . . . . . . . . 114

Deflection . . . . . . . . . . . . . . . . 115

Installation . . . . . . . . . . . . . . . 117

Removal . . . . . . . . . . . . . . . . . 116

Drive Chain Tension . . . . . . . . . . . 107

Driver Awareness . . . . . . . . . . . . . . . 14

Driveshaft Bearing . . . . . . . . . . . . . . 96

Driving Downhill . . . . . . . . . . . . . . . 17

Driving in Hilly Terrain . . . . . . . . . . 18

Driving on Slippery Surfaces . . . . . . 16

Driving Responsibly. . . . . . . . . . . . . 21

Electrical Connections . . . . . . . . . . 129

Engine Break-In . . . . . . . . . . . . . 76-77

Engine Protection . . . . . . . . . . . . . . 128

Engine Safety . . . . . . . . . . . . . . . . . . 10

Engine Stop Switch . . . . . . . . . . . . . 82

Environment . . . . . . . . . . . . . . . . . . . . 6

Exhaust System . . . . . . . . . . . . . . . 106

FRA Position, M10. . . . . . . . . . . . . . 60

Front Rear Scissor Stop . . . . . . . . . . 55

Front Suspension Adjustments. . 45-47

Front To Rear Coupling . . . . . . . . . . 55

FRSS. . . . . . . . . . . . . . . . . . . . . . . . . 55

Fuel. . . . . . . . . . . . . . . . . . . . . . . 79-80

Fuel Filter . . . . . . . . . . . . . . . . . . . . 102

Fuel Lines . . . . . . . . . . . . . . . . . . . . 102

Fuel Pump. . . . . . . . . . . . . . . . . . . . 102

Fuel System Deicers. . . . . . . . . . . . . 80

Gauge Cleaning . . . . . . . . . . . . . . . . 44

Grab Handle Adjustment . . . . . . . . . 32

Handlebar Adjustments . . . . . . . . . . 64

Headlight Adjustment. . . . . . . . . . . . 31

Headlight Bulb Installation . . . . . . 111

Headlight Bulb Removal . . . . . . . . 111

High Temperature Light. . . . . . . . . 104

Hood Latches . . . . . . . . . . . . . . . . . . 73

Hot Surface Warning . . . . . . . . . . . . 24

Summary of Contents for 600 IQ 2008

Page 1: ......

Page 2: ...r your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9921065 Rev 01 Printed in USA Pantone 425...

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: ...esign 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 publi...

Page 6: ...of your snowmobile s controls and features The Perfect Fit 45 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 68 This sectio...

Page 7: ...4...

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 t...

Page 9: ...hat 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...

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...

Page 11: ...t symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The s...

Page 12: ...obile is 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 u...

Page 13: ...feet on the running boards and both hands on the handlebar grips for proper throttle brake and steering control WARNING Serious injuries may result if hands feet or clothing become entangled in the t...

Page 14: ...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...

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 equipm...

Page 16: ...e necessary for stopping Excessive Speed 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...

Page 17: ...own 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...

Page 18: ...ow 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 co...

Page 19: ...th the full up and full down steering positions Driving on Slippery Surfaces WARNING Ice and snow build up may interfere with the steering of your machine result ing in serious injury or death Keep th...

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 res...

Page 21: ...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 th...

Page 22: ...x 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...

Page 23: ...down the snow in front of the machine so that when the throttle is opened the snowmobile will be able to climb up and over the snow WARNING Do not drive for prolonged periods on blacktop gravel or ice...

Page 24: ...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 sp...

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 mi...

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 W...

Page 27: ...perator and ONE passenger only For more information about operating with a passenger see page 13 Hot Surface Warning The hot surface warning is located near the rear of the tunnel WARNING HOT SURFACE...

Page 28: ...behind before and while back 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...

Page 29: ...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 30: ...n 2 Skis 3 Front Bumper do not use for pulling or dragging the snow mobile 4 Hood 5 Headlight 6 Windshield 7 Handlebar 8 Mirrors if equipped 9 Operator Seat 10 Passenger Seat Touring 11 Backrest Touri...

Page 31: ...Engine Stop Switch 6 Throttle Control 7 Recoil Starter Handle 8 Hood Hold Down Straps 9 Console Storage 10 Parking Brake Lock 11 Handlebar Grip Warmer Switch 12 Thumbwarmer Switch 13 Electronic Rever...

Page 32: ...he handle bars and brake lever do not contact any other snowmobile components at any steering position AND at any RIDER SELECT position Do not use RIDER SELECT positions 6 or 7 unless riding condition...

Page 33: ...o not lubricate the RIDER SELECT mechanism Doing so could cause loss of control and result in serious injury or death The RIDER SELECT mecha nism is lubricated for life at the factory WARNING Some aft...

Page 34: ...rea is 30 lbs 14 kg Install only accessories specifically approved for this model by Polaris Always secure cargo before operat ing Do not exceed the weight limit Do not allow a passenger to sit on the...

Page 35: ...er Grab Handle On some Touring models the position of the passenger grab handles can be adjusted for rider preference 1 Unscrew and remove the knob assemblies that secure the grab handles 2 Reposition...

Page 36: ...d 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 th...

Page 37: ...icator 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 Eng...

Page 38: ...peedometer 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 automa...

Page 39: ...engine RPM whichever setting is selected regardless of the display pro gram being viewed Performance Program The Performance Program automatically displays either speed or tachometer whichever is opp...

Page 40: ...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 trave...

Page 41: ...hing 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...

Page 42: ...e 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 tem...

Page 43: ...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 NOTE The gauge reads barometric pressure and all...

Page 44: ...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 M...

Page 45: ...val 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 T...

Page 46: ...ompartment 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 NOTE Note the ori...

Page 47: ...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 cle...

Page 48: ...e 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 cond...

Page 49: ...ne 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 ret...

Page 50: ...sion 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 a...

Page 51: ...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 bot tom out harshly o...

Page 52: ...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...

Page 53: ...first measurement with no rider and with the rear suspension at full extension NOTE The rear bumper may need to be lifted upward slightly to fully extend the rear sus pension Next have the rider drop...

Page 54: ...X sag X Y If the measured sag is incorrect adjust the FRA position and or rear torsion spring preload NOTE This is only an initial setup and final spring preload may vary based on rider preference an...

Page 55: ...hree position cam using the engine spark plug tool Adjustment is easiest when the cam is rotated from low to medium and then to high Rotating directly from low to high will require significantly more...

Page 56: ...ling If a rider prefers more 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...

Page 57: ...urn the adjustment knob 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 slightly then te...

Page 58: ...ar suspension 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...

Page 59: ...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 performance An...

Page 60: ...est 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 accelera...

Page 61: ...e take the time to read and understand all the possible adjustments available with this suspen sion M 10 Static Sag and Ride Height Settings Static sag describes the difference in height of the rear b...

Page 62: ...measure the distance from the ground to the top of the bumper dimension Y and record it 3 Subtract Y from X and you will have the SAG setting X Y sag setting Example 21 17 4 The correct amount of SAG...

Page 63: ...hex bolts 1 attaching the rear lower shock cross shaft to the rail beam 3 Using a 9 16I wrench loosen the jam nuts 2 on the preload bolts 4 Adjust the preload bolts 3 to the desired FRA position 5 Ti...

Page 64: ...to adjust the preload and change the sag See your Polaris dealer for assistance NOTE Whenever ordering any of the retainers listed in the chart always order the retainer insert as well The insert is...

Page 65: ...trol Lean toward the 4 setting for comfort and toward the 3 setting for aggressive riding 2 For full hole adjust ments remove the 5 16I nut and flat washers from the lower attachments of the limiter...

Page 66: ...t and reduce rear suspension travel Initial M 10 Suspension Set up Chart These charts are a guideline to be used for initial suspension set ups Your set up may vary based on your desired riding style...

Page 67: ...ts on the bottom of the adjuster block turn handle bar to left or right for access to back nuts NOTE If necessary pry the blocks apart with a screwdriver 3 Adjust the handlebar to the desired height B...

Page 68: ...mobile 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 fo...

Page 69: ...reased wear to the brake pads will result from increased braking Extended wear brake pad kits are avail able See your dealer CAUTION Always install wear strips before installing studs Failure to insta...

Page 70: ...oper 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...

Page 71: ...ystem 72 Recoil Rope 73 Coolant Level 103 Parking Brake Lock Brake Lever Brake System 70 71 108 Auxiliary Shut Off Switch Engine Stop Switch 74 Ignition Switch 74 Taillight Brakelight Headlight 74 Sus...

Page 72: ...e 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 position withou...

Page 73: ...es low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 110 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed che...

Page 74: ...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 75: ...NG Ice and snow build up may interfere with the steering of your machine result ing in serious injury or death Keep the underhood area free of snow and ice WARNING Operating the snowmobile with a dama...

Page 76: ...ays 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 en...

Page 77: ...witch 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 te...

Page 78: ...oes 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 Engaging the starter...

Page 79: ...ree 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 open ings and mac...

Page 80: ...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 Cooling...

Page 81: ...es shut off the engine and lower the machine to the ground 5 Grasp the skis by their front loops and move them from side to side to loosen snow and ice WARNING A loose track or flying debris could cau...

Page 82: ...sparks in or near the area where refueling 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 s...

Page 83: ...es per gallon 8 16 ml per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol Polaris also recommends...

Page 84: ...ld result in engine damage This is especially important when the machine is operated in mountainous ter rain Always maintain a visible level of oil in the tank If oil is not visible continued operatio...

Page 85: ...eration 1 Sit on the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pres sure on the pivot pin in the direction shown in the illustration 4 Apply a s...

Page 86: ...play 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 If an emergency exi...

Page 87: ...See page 82 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 Inter...

Page 88: ...or transmission 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 veh...

Page 89: ...n reverse NOTE The maximum engine RPM will be 6000 when in reverse NOTE If the engine stops running the snowmobile will be in forward gear when it s restarted Disengaging Reverse 1 Stop the snowmobile...

Page 90: ...e the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary WARNING Objects towed with a rope have no braking power and can easily col...

Page 91: ...should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision E...

Page 92: ...he manual You must inspect the air intake system on your snowmobile prior to each use including the airbox foam filter and hood foam filters and clean these components as necessary Polaris considers t...

Page 93: ...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 94: ...240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 113 I I I Drive Belt Condition 114 I I I I Clutches 113 C C C Belt Tension I I I I Clutch S...

Page 95: ...I I I Brake System 70 108 I Brake Fluid 109 R FUEL MANAGEMENT Idle RPM I I I Throttle Lever 83 I I I I I Oil Pump Lever synchronize I I I Throttle Cable 96 L L L Throttle Position Sensor I I I Fuel L...

Page 96: ...l I I I I Cooling Fins and Shroud I I I I Drive Shaft Bearing 96 L L L I Jackshaft Bearings 128 L L L I Skags Wear Bars 125 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 107 I I I I...

Page 97: ...tenance Table beginning on page 90 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the...

Page 98: ...95 MAINTENANCE Lubrication Rear Suspension M 10 128 Rear Suspension M 10 136 Rear Suspension...

Page 99: ...r 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 wit...

Page 100: ...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 130 for the...

Page 101: ...from the plug 4 Install a new sealing washer on the drain plug NOTE 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 102: ...lugs every 2000 2500 miles 3200 4000 km CAUTION 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 eng...

Page 103: ...i cates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates over heating caused by use of an improper spark plug or incorrect...

Page 104: ...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 th...

Page 105: ...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 compounds may occur Replace...

Page 106: ...60 antifreeze 40 water mixture See page 130 for Polaris products NOTE Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and coolin...

Page 107: ...ler for service Add coolant if the level is low NOTE Engine performance will be reduced if you continue operating when the high temperature light is on Flushing the Cooling System To ensure that the c...

Page 108: ...lant bottle to the maximum mark 5 Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air 6 Stop the engine and check the coolant...

Page 109: ...ly before inspecting 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 pi...

Page 110: ...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 111: ...lace when thickness is less than 1 16I 1 5 mm Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops bring the machine to an autho rized Polaris deale...

Page 112: ...e fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rap idly absorbs moisture from the air The moisture causes the boiling tempera ture...

Page 113: ...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 and release...

Page 114: ...t 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 B...

Page 115: ...llight 5 Install a new bulb Reinstall the socket assembly 6 Secure the storage compartment door IQ SwitchBack 1 Remove the screws securing the taillight lens Remove the lens 2 Push the bulb inward and...

Page 116: ...pplement for recommended center distance for your machine If adjustment is necessary see your dealer WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shif...

Page 117: ...racks and excessive looseness Replace the belt if any of these conditions exist See Drive Belt Troubleshooting on page 136 Always carry a spare drive belt for emergency use Store the spare belt on top...

Page 118: ...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 116 Turn the wrench clockwise slightly to remove pressure from the sheaves 2...

Page 119: ...en threaded hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves open far enough to remove the belt If the wrench does not turn readily rotate the driven clutch counter...

Page 120: ...eparate the sheaves as outlined in the belt removal proce dures 2 Rotate the L wrench counterclockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the L wre...

Page 121: ...t safely lift and support the rear of the snow mobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire length of each rod Bend the track to...

Page 122: ...ional wheel kits are available See your dealer for more information NOTE Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty WARN...

Page 123: ...istance see chart ahead of the center of the rear idler wheel NOTE Measure at the point where the weight is hanging WARNING Moving parts can cut and crush body parts When performing the checks and adj...

Page 124: ...e equal adjust ment on both sides of the track 8 Repeat the measurement on the other side of the track NOTE Check more frequently when the machine is new 9 Start the machine and slowly rotate the trac...

Page 125: ...s 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...

Page 126: ...123 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary...

Page 127: ...etween the skis at point X should be 1 8I to 1 4I 3 6 mm greater than the measurement at point Y NOTE If the skis are misaligned we recommend that your dealer cor rect the alignment since camber adjus...

Page 128: ...he machine so the skis are approximately 6I 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse...

Page 129: ...ime 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...

Page 130: ...emaining 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 preservatio...

Page 131: ...ine 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 o...

Page 132: ...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 suitab...

Page 133: ...3 VES II Synthetic 2 Cycle Engine Oil 2 5 gal Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun...

Page 134: ...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...

Page 135: ...w 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 Us...

Page 136: ...blem 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 clutchin...

Page 137: ...climb ing Set static sag see page 50 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag Adjust limiter straps see page 53 Machine darts from side to side Check ski...

Page 138: ...heck track tension see page 120 Front end pushes Check for worn skags Check for binding suspension shafts and grease all pivot points Shorten front limiter strap Install single skags see your dealer S...

Page 139: ...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 140: ...n 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 low...

Page 141: ...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 mod...

Page 142: ...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 143: ...t 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 deale...

Page 144: ...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 145: ...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 146: ...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 147: ...covered by this warranty This includes compo nents whose failure increases the snowmobile engine s emissions To the extent they are present on your snowmobile engine this includes electronic controls...

Page 148: ...es beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris can deny an emissions warranty claim if any specified critical...

Page 149: ...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 150: ...147 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 151: ...148 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 152: ...104 Customer Service 137 D DET 33 Detonation Elimination Technology 33 Digital Display 34 Disabled Operators 12 D Drive Belt 19 114 117 Adjustment 115 Condition 114 Deflection 115 Installation 117 Re...

Page 153: ...pection 126 Pressure Cap Warning 23 R Radiator Compartment Access Panel 31 Rail Slide Wear 126 Rear Rear Scissor Stop 56 Rear Suspension Adjustments 48 49 Rear To Front Coupling 56 Recoil Rope 73 Reco...

Page 154: ...69 82 Torque Stop 117 Torsion Spring Preload IQ 52 Towing 87 Track 72 Track Alignment 122 Track Care for Storage 129 Track Inspection 118 Track Lubrication 119 Track Maintenance 118 122 Track Safety...

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Summary of Contents for 600 IQ 2008

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Polaris 600 IQ 2008, Owner'S Manual

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Summary of Contents for 600 IQ 2008

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