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83

MAINTENANCE

Clutch System

n

Drive Belt Condition

Periodically check the condition and tension of the drive belt, and 
always carry a spare. Inspect the belt for signs of excessive wear: frayed 
edges, missing cogs, cracks and excessive looseness. Replace the belt if 
any of these conditions exist. See Drive Belt Troubleshooting on page 
106.

Always carry a spare drive belt for emergency use. Store the spare belt 
on top of the electrical box, which is mounted to the clutch cover.

For improved drive-away during extremely cold temperatures, remove 
the belt and warm it to room temperature. Reinstall it before starting the 
snowmobile.

n

Drive Belt Deflection

Measure belt deflection with both 
clutches at rest and in their full 
neutral position.

Place a straight edge (1) on the 
belt and apply downward pressure 
while measuring at point 2. This 
measurement should be 1 1/4

I

 

(3.2 cm).

Drive Belt Adjustment

1. Install the L-wrench into the open threaded hole in the outer sheave 

of the clutch (see page 84). Turn the wrench clockwise 

slightly

 to 

remove pressure from the sheaves.

2. Loosen the 7/16

I

 jam nut on the belt width adjuster.

3. Using a 1/8

I

 Allen wrench, turn the set screw inward (clockwise) to 

increase the distance between the sheaves or outward (counter-
clockwise) to decrease the distance.

4. Tighten the jam nut. Remove the L-wrench and store it in the tool 

kit.

1

2

Содержание 600 IQ Racer

Страница 1: ...PMS 419 Snowmobile Owner s Manual for Maintenance and Safety 600 IQ Racer...

Страница 2: ...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...

Страница 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Страница 4: ...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 9922855 Rev 01 Printed in USA 9922855 PMS...

Страница 5: ...sign and development of your POLARIS vehicle making it the finest machine we ve ever pro duced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations i...

Страница 6: ...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...

Страница 7: ...of your snowmobile s controls and features The Perfect Fit 29 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 40 This sectio...

Страница 8: ...4...

Страница 9: ...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...

Страница 10: ...at snowmobiles conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE stan dards Our muffler systems are designed to reduce noise levels and must not be altered...

Страница 11: ...the spaces pro vided Vehicle Model Number ___________________________________________________ Tunnel VIN ____________________________________________________________ right side of tunnel Engine Serial...

Страница 12: ...rsonal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided...

Страница 13: ...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 di...

Страница 14: ...n off the igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation WARNING Serious injury can occur if fingers or cloth...

Страница 15: ...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 shatterpro...

Страница 16: ...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 tio...

Страница 17: ...speed limits Always be alert and pay attention to 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...

Страница 18: ...a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Never travel on frozen bodies of water unless you have first veri...

Страница 19: ...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...

Страница 20: ...terfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage Driving on Slippery Surfaces WARNING Never attempt an...

Страница 21: ...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...

Страница 22: ...ance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you...

Страница 23: ...is a complex 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 W...

Страница 24: ...nd 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 a...

Страница 25: ...ificate For their pro tection as well 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 Jumpi...

Страница 26: ...3 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...

Страница 27: ...ING Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with this guard removed Never run engine with drive belt removed Never service clutches you...

Страница 28: ...ed helmet eye protection and 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 approve...

Страница 29: ...25 FEATURES Safety Decals and Locations Track Warning No Passenger Warning Operation Warning...

Страница 30: ...witch Tether Switch 3 Master Cylinder 4 Engine Stop Switch 5 Throttle Control 6 Recoil Starter Handle 7 Hold Down Straps 8 Fuel Filler Cap 9 Choke Control 10 Hand Thumbwarmer Switch 11 Brake Lever 12...

Страница 31: ...GON mode for normal trail riding Unnecessary extended or excessive use of DRAGON mode can result in severe engine damage which is excluded from POLARIS warranty coverage DRAGON mode usually heats up t...

Страница 32: ...aged at the starting line depress and hold the DRAGON button on the left handlebar 1 3 Slowly advance the throttle to the wide open position while keeping the button depressed 4 Release the button whe...

Страница 33: ...and then customizing each adjustment individually to suit rider preference The machine should be methodically tested one change at a time under the same conditions trail and snow conditions vehicle s...

Страница 34: ...one inch of pre load beyond the factory settings and ensure that both sides are adjusted the same When decreasing preload make sure at least two turns of preload are hold ing the spring between the r...

Страница 35: ...y 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 Shock Damping Walker Evans Sh...

Страница 36: ...tyle With a little experimentation each rider can find a preferred setup These adjustments are easy to make involve very little time or effort and greatly affect the ride In deep snow a new rail slide...

Страница 37: ...on The following information is provided only as a guideline to be used for initial suspension set up Your set up may vary based on your desired riding style Knob Adjustments Turn the knob toward the...

Страница 38: ...here are two types of rear suspen sion coupling 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 amoun...

Страница 39: ...ng 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 o...

Страница 40: ...ation move the stop to the rearward upper position The stop may also be rotated to a lower position for even more weight transfer if desired Low Position This setting will increase weight transfer Med...

Страница 41: ...the bolts Accessories POLARIS offers a wide range of accessories for your snowmobile to help make each ride more enjoyable Use only POLARIS parts and accessories on your POLARIS snowmo bile Use of una...

Страница 42: ...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 T...

Страница 43: ...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...

Страница 44: ...Page Drive Belt Condition 83 Steering System 44 Recoil Rope 45 Coolant Level 72 Parking Brake Lock Brake Lever Brake System 42 43 76 Auxiliary Shut Off Switch Engine Stop Switch 46 Tether Switch Strap...

Страница 45: ...oper operation Read and Understand Your Owner s Manual Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience n Throttle Lever...

Страница 46: ...ke lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 77 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could res...

Страница 47: ...light will illuminate if the parking brake lever lock is set while the engine is running It will also illuminate when the service brake is in use If the parking brake light does not come on when the p...

Страница 48: ...properly lubricated n Track WARNING Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death Alw...

Страница 49: ...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...

Страница 50: ...Check the auxiliary shut off switch for proper operation Push the switch down to stop the engine Pull it up to allow restarting n Tether Switch Remove the tether from the switch to make sure the engin...

Страница 51: ...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 en...

Страница 52: ...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 fit ting machined...

Страница 53: ...r flow rates All POLARIS oils are compatible with each other See page 100 for the part numbers of POLARIS products Fuel Recommendations Always use premium non oxygenated 92 octane fuel in this snowmo...

Страница 54: ...r the part numbers of POLARIS products TIP When using oxygenated fuel containing ethanol additional alcohol deicers or water absorbing additives should not be used Drive Belt Break In The break in per...

Страница 55: ...oggle to the OFF position If the engine slows or wants to stop use intermittent choking to the HALF CHOKE position NOTICE Operating the vehicle immediately after cold starting could cause engine damag...

Страница 56: ...fire resulting in serious injury or death When traveling on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat and result in brake failure n Engine Stop...

Страница 57: ...to securely support the rear of the snowmobile at the rear bumper The track should be about 4I 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throt...

Страница 58: ...ICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refu eling Add oil as needed Always maintain a visible level of oil...

Страница 59: ...e performance A lean mixture may be caused by things like fuel line restrictions for eign matter in the carburetor or clogged fuel filters A rich mixture may be caused by snow build up on the pre filt...

Страница 60: ...e The main jet installed in production is not correct for all altitudes and or temperatures See page 70 for more information NOTICE A main jet that s too small will cause a lean operating condition an...

Страница 61: ...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 betwee...

Страница 62: ...e with a minimum octane level of 91 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 Specificat...

Страница 63: ...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...

Страница 64: ...00 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 82 I I I Drive Belt Condition 83 I I I I Clutches 82 C C C Belt Tension I I I I Clutch Sheaves 82 I...

Страница 65: ...I I Brake System 42 76 I Brake Fluid 77 R FUEL MANAGEMENT Pilot Air Screws I I I Carburetor synchronize 70 I I I Idle RPM I I I Throttle Lever 41 I I I I I Throttle Cable 64 L L L Choke Cable 64 L L...

Страница 66: ...I Drive Shaft Bearing 96 L L L I Jackshaft Bearings 96 L L L I Skags Wear Bars 93 I I I I I Ski Saddle Spindle Bolts I I I I I Steering Post U Joint 63 L L L L L Steering Arm s L L L L I Upper Lower S...

Страница 67: ...n Lubricate the suspension pivot shafts with POLARIS Premium All Sea son Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 59 and before seasonal storage When operat...

Страница 68: ...turn the handlebars to the left and lubricate liberally as shown Choke and Choke Cable Lubricate the choke slide and cables lightly with oil or grease Before turning the engine off operate the choke i...

Страница 69: ...oil level between the safe marks on the dipstick Clean the magnetic plug on the dipstick whenever checking or changing oil POLARIS recommends the use of POLARIS Synthetic Chaincase Lube See page 100 f...

Страница 70: ...conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile Spark Plug Condition Spark plug condition is indicative of engine operation The spark plug...

Страница 71: ...y adjustments Wet Fouled 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 caus...

Страница 72: ...re operating the snowmobile Variable Exhaust System VES Maintenance of the VES is limited to a periodic inspection and cleaning of system components Bring the machine to an authorized POLARIS dealer t...

Страница 73: ...1600 km or annually Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal dete rioration from weather and fuel compoun...

Страница 74: ...engine damage Have your POLARIS dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or...

Страница 75: ...may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the gasoline warnings found on page 47 1 Turn the fuel valve off 2 Position a container or shop to...

Страница 76: ...ute with water Never exceed a 60 antifreeze 40 water mixture See page 100 for POLARIS products NOTICE Never add tap water to the cooling system Minerals cause deposits and may react adversely with the...

Страница 77: ...g 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 m...

Страница 78: ...Cycle the RPM from idle to enough RPM 4000 to get coolant to flow but not enough to engage the clutch This allows air to bleed from the rear crossover tube TIP There must be enough coolant flow to pu...

Страница 79: ...r the exhaust system to cool Never perform this procedure with the engine running Drive Chain Tension Check drive chain tension weekly and before each long trip To obtain correct chain tension 1 Rotat...

Страница 80: ...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 t...

Страница 81: ...nt and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function View the brake fluid level through the sight glass on the top of the mas ter cylinde...

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

Страница 83: ...e center of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be ai...

Страница 84: ...oistened towel Headlight Bulb Removal 1 Remove the plenum covering from the headlight assembly 2 Pinch the ends of the spring 1 together and lift until it releases from the spring retainer 3 Lift spri...

Страница 85: ...pring back into the housing placing it around the wire harness 5 Reinstall the plenum covering on the headlight assembly 6 Verify headlight aim Taillight Brakelight Replacement 1 Remove the screws sec...

Страница 86: ...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 ar...

Страница 87: ...ature Reinstall it before starting the snowmobile n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position Place a straight edge 1 on the belt and...

Страница 88: ...to a complete stop 2 Apply the brake or lock the parking brake if equipped 3 Open the hood and remove the left side panel Remove the clutch guard retaining pin and open the clutch guard 4 Rotate the d...

Страница 89: ...ification numbers so that you can read them If required separate the sheaves as out lined in the belt removal procedures 3 Rotate the L wrench counterclockwise to tighten the sheaves while working the...

Страница 90: ...rts Never perform track measurement or adjustments with the engine run ning Track Inspection 1 Using a hoist safely lift and support the rear of the snow mobile off the ground WARNING Broken track rod...

Страница 91: ...e and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for extended periods on ice and other su...

Страница 92: ...gine off 2 Lift the rear of the machine and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of...

Страница 93: ...vide equal adjust ment on both sides of the track 9 Repeat the measurement on the other side of the track TIP Check more frequently when the machine is new 10 Start the machine and slowly rotate the t...

Страница 94: ...Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track r...

Страница 95: ...91 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all steering system fasteners and tighten if necessary...

Страница 96: ...our POLARIS dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt...

Страница 97: ...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...

Страница 98: ...ekly basis or before any long trip n Check suspension mounting bolts for tightness n Check rear idler wheel bolts for tightness See page 89 n Check rear idler adjusting bolt locknuts for tightness n C...

Страница 99: ...g surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with...

Страница 100: ...Repair Manual See your dealer Engine and Carburetor Protection Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine parts during stor...

Страница 101: ...torage 2 Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward 3 Remove the spark plug s 4 Rotate the engine slowly watching the p...

Страница 102: ...h dielectric grease and re connect 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...

Страница 103: ...Turn the fuel valve clock wise to OFF to shut off the fuel supply Turn the valve counter clockwise to ON to turn the fuel supply on The fuel valve is located under the hood 2 Be sure the fuel cap is s...

Страница 104: ...Cycle Engine Oil ltr 2877888 VES Gold Plus Synthetic 2 Cycle Engine Oil 4 ltr Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 95 l 2872951 Synthetic Chaincase Lubricant 12 oz 355 ml Gre...

Страница 105: ...belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for application Replace the drive belt Clutch alignment out of spec SEE YOUR DEALER Engine mount broken or loose...

Страница 106: ...ssive belt sheave clearance SEE YOUR DEALER Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Poor fuel quality Use 92 octane fuel Engine doesn t turn Seized engine SEE YOUR DEALER Se...

Страница 107: ...xture is too lean A main jet that is too small will cause seizure resulting in loss of power This indicates a major engine problem that must be repaired before operating SEE YOUR DEALER Engine lacks p...

Страница 108: ...ct shock Change to lighter valving if FOX shock Check track tension see page 88 Too much weight transfer when climb ing Adjust torsion spring preload see page 33 Adjust limiter straps Too little weigh...

Страница 109: ...ease IFS preload if equipped see page 30 Install single skag see your dealer Rotate RRSS to high position see page 36 Steering is heavy Make sure spindles and all steering components turn freely Check...

Страница 110: ...high ambient temperatures 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 an...

Страница 111: ...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 followi...

Страница 112: ...owner reports theft A In addition to notifying the proper law enforcement officials the owner must call POLARIS Customer Service B Owners must provide their name address telephone number and the mode...

Страница 113: ...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 or used for purpos...

Страница 114: ...t the appropriate personnel at POLARIS if additional assistance is needed This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the...

Страница 115: ...dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warrant...

Страница 116: ...s authorized location This policy does not apply to Safety Bulletins How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authoriz...

Страница 117: ...tices regarding your vehicle If Purchased From A Private Party If you purchase a POLARIS product from a private citizen outside of the country in which the vehicle was originally purchased all warrant...

Страница 118: ...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...

Страница 119: ...xcludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty als...

Страница 120: ...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...

Страница 121: ...117 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Страница 122: ...118 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Страница 123: ...oolant 72 Coolant Level 72 Cooling System 72 74 Cooling System Bleeding 73 74 Cooling System Flushing 73 D Disabled Operators 12 DRAGON Ignition System 27 28 DRAGON Mode Facts 27 Drive Belt Adjustment...

Страница 124: ...P Parking Brake Lever Lock 43 Passenger Warnings 23 Preload IFS Shock Spring 30 Pre Ride Checklist 40 Pre Ride Suspension Inspection 94 Pressure Cap Warning 23 R Rail Slide Wear 93 Rear Rear Scissor S...

Страница 125: ...orsion Spring Tension 33 Towing 57 Track 44 Track Alignment 90 Track Care for Storage 98 Track Inspection 86 Track Lubrication 87 Track Maintenance 86 90 Track Safety 10 Track Tension 32 88 89 Track W...

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