Polaris 600 IQ Touring Page 109 Owner'S Manual Download

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106

MAINTENANCE

Clutch System

Drive Belt Removal

NOTICE:

Do not attempt to remove the drive belt after operating in reverse. The

snowmobile must be stopped after forward motion to prevent damage

to components during belt removal.

1. Stop the engine after operat-

ing in a forward motion.

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.
5. Remove the left side panel.
6. Rotate the driven clutch

counterclockwise 1/4 turn

by hand to ensure forward

engagement before attempting to remove the belt.

7. Locate the L-wrench in the tool kit. Install the wrench into the open

threaded hole in the outer sheave of the clutch (

8. 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 counterclockwise an additional 1/4 turn by hand and

try again.

9. Grasp the belt at the lower edge and remove it.

Summary of Contents for 600 IQ Touring

Page 1: ......

Page 2: ...antone 426C For 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 9922288 Rev 01 Printed in USA ...

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: ...r 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 Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is i...

Page 5: ...improvements in the design 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 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 ...

Page 6: ... of your snowmobile s controls and features The Perfect Fit 50 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 64 This section explains procedures that must be performed before riding Operation 72 This section explains proper engine break in operation of features and general operating procedures Maintenance 83 This section...

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 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: ...of our environment Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends 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 ...

Page 10: ...laris 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 _________________________________________________________ lower right side of the tunnel Engine Serial Number on recoil housing _____________________________________ Key Number ______________________________...

Page 11: ...with their meanings before reading the manual The safety alert symbol on your vehicle or in this manual indicates the potential for serious injury WARNING A WARNING indicates a potential hazard that may result in serious injury or death CAUTION A CAUTION indicates a potential hazard that may result in minor injury NOTICE A NOTICE indicates a situation that may result in damage to the vehicle ...

Page 12: ...e 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 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 ...

Page 13: ...behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures Stay Clear of Engine Never attempt adjustments with the engine running Turn 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 o...

Page 14: ...s ride in a group of other snowmobilers Always tell someone where you re going and how long 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...

Page 15: ...r will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be pre...

Page 16: ...ith two people on board More space is required to make turns and longer distances are needed for stopping Make sure the passenger remains seated behind the driver facing forward with both feet placed firmly on the running boards Slow down and avoid jumping your snowmobile Snowmobiles designed for two riders should never be operated with more than two people on board When traveling with a passenger...

Page 17: ...hysical disabilities have an increased risk of loss of control which could result in serious injury or death Do not allow disabled persons to operate this vehicle Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer Do not exceed carrier and rack weight limits and do not allow a passenger to sit on the seat back or the cargo carrier ...

Page 18: ...the trail ahead If your speed is 40 MPH 64 km h your snowmobile is traveling about 60 feet 18 m per second If you look back for only two seconds your snowmobile will travel about 120 feet 36 m If your speed is 60 MPH 96 km h your snowmobile will travel about 180 feet 55 m in two seconds Traveling at night requires extra caution Check headlight and taillight to ensure proper operation and don t ove...

Page 19: ...o difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your snowmobile will drown out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or highways Steep embankments may also hide your view Always leave yourself a way out Variances in snow depth and or water currents ma...

Page 20: ...snow 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 mountainous 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 21: ...m this check in both the full up and full down steering positions Driving Downhill When riding downhill shift your weight to the rear of the snowmobile and reduce your speed to a minimum Apply just enough throttle to keep the clutch engaged allowing the engine s compression to help slow the snowmobile and keep it from rolling freely downhill WARNING When driving on long downhill stretches pump the...

Page 22: ... If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible rollover 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 conti...

Page 23: ...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 throttle with enough authority to put t...

Page 24: ... 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 snowmobile becomes stuck...

Page 25: ...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 26: ... 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 27: ... 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 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 clutches...

Page 28: ...e left console For more information on operating with a passenger see page 13 WARNING This vehicle is designed for operator and ONE passenger only Track Warning WARNING Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death One Passenger Warning Track Warning ...

Page 29: ...injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Machine stopped 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 fo...

Page 30: ... approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age require ments 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...

Page 31: ...ragging the snowmobile 4 Hood 5 Headlight 6 Windshield 7 Operator Seat 8 Passenger Seat 9 Backrest 10 Passenger Grab Handle 11 Cargo Bag 12 Grab Handle Heater Switch 13 Taillights 14 Rear Bumper 15 Snow Flap 16 Track 17 Suspension 3 4 5 6 2 1 7 8 9 12 13 14 15 16 17 10 11 ...

Page 32: ... 6 Hood Hold Down Straps 7 Handlebar Grip Warmer Switch 8 Thumbwarmer Switch 9 Electronic Reverse Button 10 MFD Control 11 Headlight Dimmer Switch 12 Parking Brake Lock 13 Brake Lever 14 Engine Stop Switch 15 Throttle Control 16 Ignition Switch 16 1 13 14 15 12 7 8 9 10 11 3 1 6 4 5 ...

Page 33: ...ve the backrest for ward for operator use or rear ward for passenger use 3 Always tighten the knobs securely after adjusting Adjustable Headlights Move the adjuster to the left to lower the headlight beam Move the adjuster to the right to raise the headlight beam Radiator Compartment Access Panel The access panel is provided for cleaning debris from the radiator Operator Passenger Raise Lower ...

Page 34: ...fore operating Do not exceed the weight limit Do not allow a passenger to sit on the seat back or the cargo area 1 Remove the cargo bag 2 Push down on the seat latch lever which is located at the lower rear of the passenger seat 3 Lift up the seat and remove it from the chassis 4 Reverse the procedure to reinstall the seat Press down firmly on both sides of the seat to engage the latch Verify that...

Page 35: ...ted for rider preference 1 Unscrew and remove the knob assemblies that secure the grab handles 2 Reposition the grab handles to one of the three available posi tions on the grab handle tube between the operator seat and the passenger seat 3 Reinstall the knob assemblies and tighten securely Knob Assembly ...

Page 36: ...ntact 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 conditions require it Operation in position 6 or 7 can reduce vehicle handling for other types of riding and result in serious injury or death Choosing the Best RIDER SELECT Position Position Riding Style 1 2 3 Relaxed Trail Riding Rider weight is s...

Page 37: ... Do not lubricate the RIDER SELECT mechanism Doing so could cause loss of control and result in serious injury or death The RIDER SELECT mechanism is lubricated for life at the factory WARNING Some aftermarket accessories including windshields and cargo bags may interfere with the handlebar Such accessories could limit your ability to steer the vehicle and or may contact the brake lever This could...

Page 38: ...ed 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 is unable to detect detonation The rider will experience a loss of power The sensor must be reconnected or repaired to regain full power See your Polaris dealer...

Page 39: ...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 40: ...and a SET but ton bottom Specific instructions are outlined on the following pages Standard vs Metric The MFD will display either stan dard or metric units of measurement While viewing a screen that displays measurements MPH km h or tem peratures press and hold the MODE switch until the unit of measure ment changes about 10 seconds MFD Control Switch SET MODE ...

Page 41: ... 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 viewing preferences press and hold the MODE button for three seconds When the button is released the new setting becomes active and screen colors change See table below Option Analog Display Digital Display Analog Screen Digital Screen 1 Speed RPM Blue MPH Bl...

Page 42: ...m The Performance Program automatically displays either speed or tachometer whichever is opposite the analog display See page 38 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 2 Trip F if equipped with electronic fuel gauge and Clock if equipped Use the following procedures to make c...

Page 43: ...r to keep track of distance traveled Both odometers can be reset to zero 1 Enter the Performance Program 2 Press and release the SET button until the desired trip screen is active 3 Press and hold the SET button for two seconds to reset the trip odometer to zero 4 Press and release the SET button to cycle through additional screens ...

Page 44: ...uel 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 automati cally reset to zero after refueling ...

Page 45: ...e seconds 4 When the hour starts flashing press the SET switch once to advance one hour Press and hold the SET button to advance the hours quickly 5 Press and release the MODE button to save the hour The minutes will begin flashing 6 Set the minutes in the same manner 7 When finished press and release the MODE button to save the new setting If the MODE button is not pressed within ten seconds the ...

Page 46: ...ss the SET button to dis play the ambient air temperature and altitude screens Use the following procedures to make changes to these screens Hour Meter The hour meter records the total hours of engine operation since manufacture This meter cannot be reset Engine Temperature A thermometer measures water temperature giving an indication of engine temperature Air Temperature if equipped The MFD displ...

Page 47: ...n once to advance 50 feet 15 m Tip Press and hold the SET button to advance quickly by 100 foot 30 m incre ments 5 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 t...

Page 48: ... currently displayed The History Program will display the history of the Maximum Speed Maximum RPM and Service Interval settings Maximum Speed Maximum RPM 1 Enter the History Program 2 Press and release the SET button until one of the two screens is active Tip The MPH and RPM values are both reset at the same time Reset the values before each run to obtain accurate readings 3 Press and hold the SE...

Page 49: ...odometer area and ENG will flash in the icon area for five seconds each time the engine is started until the service reminder is reset Use the following procedures to reset the reminder To reset the reminder at the existing interval 1 Enter the History Program 2 Press and release the SET button until the service interval screen is active 3 Press and hold the SET button for ten seconds continuing t...

Page 50: ...active 3 Press and hold the SET button for five seconds until the hours begin to flash Immediately release the button 4 Press the button again up to five times to advance the reminder in 50 hour increments Tip The maximum interval is 250 hours 5 Press and release the MODE button to save the new settings To disable the service interval reminder 1 Press the SET button once after reaching 250 hours o...

Page 51: ...ry compart ment It has a red wire and a brown wire with a white stripe It s located about three inches down the main harness from the point where the harness connects to the MFD 3 Cut the plastic cable tie from the outside of the compartment 4 Carefully cut the bottom of the compartment opposite the wires to separate the heat sealed seams Squeeze the corners of the compart ment inward so the batte...

Page 52: ...Make sure the taped seam of the compartment faces the downward side of the wire harness 9 Install a cable tie to secure the compartment to the wire harness in the same location where the previous 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 clo...

Page 53: ...ons We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The snowmobile should be methodically tested one change at a time under the same conditions trail and snow condi tions 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 I...

Page 54: ...xceed 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 ...

Page 55: ... to control suspension stiffness 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 Shocks contain high pressure nitrogen gas Use extreme caution when handling high pressure service equipment We recommend that this work be performed by a Polaris dealer ...

Page 56: ...tance see your dealer Suspension Performance Tips Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride In deep snow a new rail slide will offer improved perfo...

Page 57: ...sing the rear suspension With the rider seated measure the distance between the ground and the rear bumper at the exact location used for measure ment X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y from X sag 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 sp...

Page 58: ... 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 effort Different rate torsion springs are available if a firmer ride is desired See your dealer for more information Soft Medium Firm ...

Page 59: ...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 ski pressure 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 60: ...uspension 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 ar...

Page 61: ...usting 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 suspension Reduced ...

Page 62: ...proved 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 initial setup and additional setup instruc tions to help you achieve your opti mum ride A scissor stop tool is also available from your dealer Track Tension Track adjustment is critical for proper handling Always ma...

Page 63: ... the adjuster block turn han dlebar to left or right for access to back nuts Tip If necessary pry the blocks apart with a screwdriver 3 Adjust the handlebar to the desired height Be sure han dlebars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when turned fully to the left or right 4 Torque the front bolts first then torque...

Page 64: ...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 65: ...lack of 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 stu...

Page 66: ...ntain 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 Install the appropriate wear strip kit See your dealer Wear strips are designed for a spec...

Page 67: ... 105 Steering System 66 Recoil Rope 65 Parking Brake Lock Brake Lever Brake System 67 68 100 Throttle Lever 65 Throttle Safety Switch 65 Auxiliary Shut Off Switch Engine Stop Switch 71 81 Ignition Switch 71 81 Taillight Brakelight Headlight 71 Coolant Level 96 Chaincase Oil Level 90 Injection Oil Level 77 Suspension Mounting Bolts 70 Skags Wear Bars 63 115 Ski Saddle and Spindle Bolts 70 Hood Stra...

Page 68: ...nd 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 position without binding or hesitation If the throttle does not func tion smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the thro...

Page 69: ...place before operating the snowmo bile n Steering System WARNING Ice and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice an...

Page 70: ...ulic system Refer to the brake bleeding infor mation on page 102 Brake Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 101 Check for the presence of air in the fluid system See page 102 for more information or see your dealer for service WARNING Continued use of spongy brakes may cause a complete loss of brakes which c...

Page 71: ... place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit 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 t...

Page 72: ...hicle 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 severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions Track damag...

Page 73: ...the follow ing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 111 Rear idler adjusting bolt locknuts Tightness Torque arm bolts Tightness Carrier and bogie wheel bolts Tightness Front torque arm limiter strap Condition Rail slide Condition 112 Track Tension 110 All rear suspension components Lubrication 88 Ski ru...

Page 74: ...ting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating n Mirror Adjustment If equipped adjust your mirrors so they can be used to their full advan tage 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 Operating Area Before driving away check your surr...

Page 75: ...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 76: ...e 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 Cooling NO...

Page 77: ...ys 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 support the rear of the snow mobile at the rear bumper The track should be approximately 4 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 allow the...

Page 78: ...rks in or near the area where refu eling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time The engine exhaust from this product contains chemicals k...

Page 79: ...etroleum based products may damage paint Always protect painted surfaces when handling fuel Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containin...

Page 80: ...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 refueling 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 S...

Page 81: ...removed from the throttle lever and the throttle cable or valves do not return to the normal closed position WARNING Operating the snowmobile with a faulty throttle 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 ...

Page 82: ...rottle 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 Tip Excessive freeplay in the throttle cable may cause the safety switch to acti vate preventing the engine from starting If this occurs return the snowmo bile to an authorized Polaris dealer for service T...

Page 83: ...arp turns Apply throttle slowly 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 starter when the engine is running Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your snowmobile is clear 3 Push the yellow reverse but ton on the left hand control ...

Page 84: ...make sure the transmission is in for ward n Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 78 for more information about the engine stop 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 ...

Page 85: ...e 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 86: ... 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 87: ...tervals 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 t...

Page 88: ...150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 104 I I I Drive Belt Condition 105 I I I I Clutches 104 C C C Belt Tension I I I I Clutch Sheaves 104 I I I I ENGINE COOLING Engine Mounts I I I I Recoil Rope I I I I Engine Torque Stop 107 I I I I Cylinder Head Bolts I I I Cylinder Base Nuts I I I I Ignition Timing BTDC I I I VES Sys...

Page 89: ... I I I Brake System 67 100 I Brake Fluid 101 R FUEL MANAGEMENT Idle RPM I I I Throttle Lever 65 79 I I I I I Oil Pump Lever synchronize I I I Throttle Cable 89 L L L Throttle Position Sensor I I I Fuel Lines 94 I I I I I Fuel Filter 94 R R Oil Filter 95 R R Oil Lines 95 I I I Air Box I I I I I ELECTRICAL Auxiliary Shut Off Switch 71 78 I I I I I Throttle Safety Switch 78 I I I I I Ignition Switch ...

Page 90: ... Oil I I I I Cooling Fins and Shroud I I I I Drive Shaft Bearing 89 L L L I Jackshaft Bearings 116 L L L I Skags Wear Bars 115 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 99 I I I I I Hood Latches 66 I I I I I Rear Wheel Idler Bolts 111 I I I I I Idler Bolt Jam Nut 111 I I I I I Rear Suspension Pivot Shafts 88 L L L Steering Post U Joint L L L Camber Alignment I I I Handlebar ...

Page 91: ...Periodic Maintenance Table beginning on page 85 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 life of the sus pension For more information about suspension lubrication and adjust ments see your Polaris dealer IQ Comfort Rear Suspension ...

Page 92: ...he 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 Front Suspension The front suspension and steering components do not require lubrica tion Fitting ...

Page 93: ...sight glass 2 Change the chain case 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 ove...

Page 94: ...om 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 seate...

Page 95: ... than intended for that plug Always use the spark plugs recommended for your snowmobile Use recommended spark plugs with the proper gap Refer to your Owner s Manual Supplement for the specific spark plug to be used in your machine Use only resistor type spark plugs Torque spark plugs to 18 22 ft lbs 24 30 Nm Check the spark plug firing end condition after the engine has been warmed up and the vehi...

Page 96: ...rburetor throttle body adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil or use of non recommended injection oil Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provid...

Page 97: ...olaris dealer Do not attempt to service the fuel pump Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 85 Fuel Lines 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 m...

Page 98: ...m Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 85 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 Allow the engine and exhaust system to cool completely 2 Open the hood 3 Inspect the muffler and pipes for cracks or d...

Page 99: ...with water Never exceed a 60 antifreeze 40 water mixture See page 118 for the part numbers of Polaris products Tip 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 reservoir bottle Filler n...

Page 100: ...wn 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 completely every two years and add a fresh mixture of antifreeze and d...

Page 101: ...vate the front of the vehicle slightly 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 ...

Page 102: ... 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 103: ... or 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 16 1 5mm Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thickness is less than 1 16I 1 5 mm Excessive L...

Page 104: ...low for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function NOTICE Brake fluid will damage decals paint and some plastics Always wipe up spills immediately Replace brake fluid at least every two years with Polaris DOT 4 high tem perature brake fluid See page 118 for the part numbers of Polaris products The brake fluid ...

Page 105: ... 2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 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 a...

Page 106: ...the bulb by its metal base and carefully separate the bulb from the harness Installing Halogen Bulbs 1 Hold the bulb by its metal base and install it into the wire harness 2 Insert the bulb into the housing 3 Connect the spring to the housing 4 Carefully flip the spring back into the housing placing it around the wire harness 5 Reinstall the plenum covering on the headlight assembly 6 Adjust headl...

Page 107: ...rmed 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 you...

Page 108: ...tion Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge on the belt and apply downward pressure while measuring at point A This measurement should be 1 1 4 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 106 Turn the wrench clockwise slightly to remove pressure from t...

Page 109: ...k the parking brake 4 Open the hood 5 Remove the left side panel 6 Rotate the driven clutch counterclockwise 1 4 turn by hand to ensure forward engagement before attempting to remove the belt 7 Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch 8 Turn the wrench clockwise until the sheaves open far enough to remove the belt If the w...

Page 110: ...m If required separate the sheaves as outlined in the belt removal procedures 2 Rotate the L wrench counter clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the wrench 4 Reinstall the side panel 5 Close and secure the hood Torque Stop Periodically check torque stop clearance With clutches in proper alignment the torque stop clearance should be 010I ...

Page 111: ...commended for your model Track Inspection WARNING Broken track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and sup port the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track alo...

Page 112: ...ide rail requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty NOTICE High speed use on hard packed surfaces is not recommende...

Page 113: ...alignment Tip Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the snowmobile 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 Tip Measure at the point where the weight is hanging TRACK TENSION D...

Page 114: ...djustment on both sides of the track 8 Repeat the measurement on the other side of the track Tip Check more frequently when the snowmobile is new 9 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 10 Check track alignment see page 112 and adjust as necessary 11 Tighten the lock nuts 12 Tighten the idler shaft bolts Torque to 35...

Page 115: ...are evenly spaced on each side If the track runs to the left loosen left locknut and tighten the left adjusting bolt If the track runs to the right loosen right locknut and tighten the right adjusting bolt 4 After adjustments are complete tighten locknuts and torque idler shaft bolts to 35 ft lbs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment n Rail Slide Wear For ease of inspection all...

Page 116: ...113 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners ...

Page 117: ...ith 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 8 to 1 4 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 adjustment...

Page 118: ...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 snowmobile so...

Page 119: ... preservation with waxes and rust inhibitors grease oil or paint The snowmobile should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components Controls and Linkage Lubricate all bushings and cables at the intervals outlined in the Periodic Maintenance Table beginning on page 85 ...

Page 120: ...es through the entire fuel system Top off with fresh fuel Do not allow the snowmobile to run out of fuel Electrical Connections Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts and hot exhaust parts Track and Suspension Moderate track tension should be maintained during summer storage The snowmobile...

Page 121: ...43 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 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 Prem...

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: ...rts from side to side Check ski alignment see page 114 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 54 Check rail slide replace if worn see page 112 Install Accu Trak dual skags see your dealer Front end pushes Check for worn skags Check for binding front suspension...

Page 126: ...l 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 fouled plugs or water ice or dirt in the gas tank or fuel line Loading machines onto trailers Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the machine comp...

Page 127: ... contained in this manual Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following 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 pro...

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 number 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 notifyi...

Page 129: ...s 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 t...

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 1500 mi 2400 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: ...abled Operators 14 Drive Belt 20 Drive Belt Adjustment 105 Drive Belt Condition 105 Drive Belt Deflection 105 D Drive Belt Installation 107 Drive Belt Removal 106 Drive Chain Tension 99 Driver Awareness 16 Driveshaft Bearing Lubrication 89 Driving Downhill 18 Driving in Hilly Terrain 19 Driving on Slippery Surfaces 19 Driving Responsibly 22 E Emission Control Information 83 Emission Control Label ...

Page 140: ...de Checklist 64 Pressure Cap Warning 24 R Rail Slide Wear 112 Rear Rear Scissor Stop 58 Rear To Front Coupling 58 Recoil Rope 65 Reverse Operation 80 81 Reverse Warning 26 Rider Capacity 13 RIDER SELECT 33 34 RRSS 58 S Safety 8 23 Safety Decals 24 27 Safety Symbols 8 Seat Latches 65 Shock Valving 52 Signal Words 8 Skags 63 115 Ski Alignment 114 Ski Pressure 56 Slide Rail and Track Cooling 73 Snow ...

Page 141: ...Towing 82 Track Alignment 112 Track Inspection 69 108 Track Lubrication 109 Track Replacement 108 T Track Tension 59 110 111 Track Warm Up 74 Track Warning 25 Traction Products 62 63 Transporting the Snowmobile 117 Troubleshooting Drive Belt Wear Burn 123 IQ Suspension 122 Troubleshooting Engine 119 121 V Vehicle Identification Numbers 7 W Warning Labels Decals 24 27 Wear Strips 63 Weight Transfer...

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