600 IQ Racer (2016) - Snowmobile POLARIS - Free user manual and instructions
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| Product Type | Snowmobile |
| Brand | Polaris |
| Model | 600 IQ Racer (2016) |
| Engine Displacement | 599 cc liquid-cooled, 2-stroke |
| Horsepower | Approximately 125 hp |
| Fuel System | Electronic fuel injection (EFI) |
| Fuel Capacity | 13.5 gallons (51 liters) |
| Cooling System | Liquid-cooled |
| Drive System | Variable speed CVT (Polaris P-85 drive clutch) |
| Suspension Front | Independent A-arm with Walker Evans shocks |
| Suspension Rear | IQ rear suspension with Walker Evans shocks |
| Track Length x Width x Lug Height | 121 x 15 x 1.25 inches |
| Brakes | Hydraulic disc brakes |
| Dry Weight | Approximately 480 lbs (218 kg) |
| Overall Length | 114 inches (290 cm) |
| Overall Width | 47 inches (119 cm) |
| Skis Stance | 42 inches (107 cm) |
| Seating | 1-person (rider) |
| Electric Start | Standard |
| Reverse | Standard (push-button reverse) |
| Hand Warmers | Adjustable |
| Maintenance Interval | Recommended every 1,500 miles or annually |
| Warranty | 1-year limited warranty |
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USER MANUAL 600 IQ Racer (2016) POLARIS
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Symbolic compass rose inside an oval frame, no text or labels presentRead, understand, and follow all of the instructions and safety precautions 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.
For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and recreational products:
- Snowmobiles • RZR® sport vehicles
- All-terrain vehicles (ATVs) • GEM® electric vehicles
- Low emission vehicles (LEVs) • VICTORY® motorcycles
- RANGER® utility vehicles
- INDIAN® motorcycles
- BRUTUS® work vehicles • POLARIS POWER® generators
- SLINGSHOT® three wheel motorcycles
- POLARIS DEFENSE® combat vehicles
We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle.
For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer® (MSD) technician.
Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.
POLARIS®
POLARIS®, IQ® and DRAGON® are trademarks of POLARIS Industries Inc.
Copyright 2015 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.
Printed in U.S.A.
2016 600 IQ Racer Owner's Manual
P/N 9926025
TABLE OF CONTENTS
Introduction 5
This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner's manual.
Safety 8
This section describes safe vehicle operation and identifies warning labels and their locations.
Features 31
This section identifies the locations of your snowmobile's controls and features.
The Perfect Fit 34
This section explains how to tailor the suspension and other features for an optimum riding experience.
Pre-Ride Inspections 48
This section explains procedures that must be performed before riding.
Operation 55
This section explains proper engine break-in, operation of features and general operating procedures.
Maintenance 64
This section defines your role, and your dealer's role, in your snowmobile's regular maintenance.
Specifications.... 104
POLARIS Products. 106
Troubleshooting.... 107
Warranty 113
Maintenance Log 121
Index 124
INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold.
Some of the illustrations and photos used in this manual are general representations. Your model may differ.
Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile 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. Make sure they know how to drive and control the snowmobile before allowing them to make longer trips. Teach them proper snowmobile courtesy, and enroll them in driver's training and safety courses sponsored by local or state organizations.
INTRODUCTION
Preservation of the Environment
POLARIS is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation.
Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation 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 removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others. We do our part by manufacturing quieter machines; we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly.
Air Pollution
POLARIS engineers continuously investigate ways to reduce emission levels of two-stroke engines. We expect our efforts to lead to the reduction of potential air pollution.
In addition to our technological research, we encourage government agencies, manufacturers, distributors, dealers, ecologists, and other interested parties to work together to develop data on environmental topics.
INTRODUCTION
Vehicle Identification Numbers
Record your snowmobile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.
NOTE: If installing an aftermarket tunnel wrap, do not cover the tunnel certification, tunnel VIN or emissions certification labels with the wrap. If the tunnel wrap doesn't provide an opening for these labels, remove the section of wrap where the labels are located.
Vehicle Model Number: ____
Tunnel VIN:
(right side of tunnel)
Engine Serial Number: ____
(right front side of engine crankcase)
SAFETY
Operator Safety
The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.
The safety alert symbol indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.
Operator Safety
Follow the recommended maintenance program beginning on page 65 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.
WARNING
Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger. They will reduce your alertness and slow your reaction time.
Snowmobiles are capable of traveling at high speeds. Use extra caution to ensure operator safety. Make sure your snowmobile 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 operation with any modifications, especially those that increase speed or power. DO NOT MODIFY YOUR MACHINE. The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury.
The warranty on your entire machine is terminated if any equipment has been added, or any modifications have been made, to increase the speed or power of the snowmobile.
SAFETY
Operator Safety Stay Clear of Track
Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation.
WARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track. Never hold the snowmobile up or stand 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.
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Line drawing of a manual lawn mower and a hand holding a no-smoking symbol (no text or labels)Stay Clear of Engine
Never attempt adjustments with the engine running. Turn off the ignition, raise the hood, make the adjustment, secure shields and guards, secure the hood, and then restart the engine to check its operation.
WARNING! Serious injury can occur if fingers or clothing contact the moving parts of an engine. Always stop the engine before attempting adjustments.
Riding Position
Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmobiles, but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.
WARNING! Improper riding position may reduce control and could result in serious injury or death. Always ride in a position that allows for control of your vehicle.
Operator Safety Riding Apparel
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever 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 prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 27.
WARNING! Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury. Always wear an approved helmet and eye protection.
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Product photo of polaris winter sports gear including jacket, pants, helmet, and boots (no text or symbols visible)SAFETY
Operator Safety
Disabled Operators
Safe operation of this rider-active vehicle requires good judgement and physical skills.
WARNING! Operators with cognitive or physical 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.
Survival Preparation
For your safety, always 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 conditions you may encounter. Such equipment may include, but is not limited to: extra clothing, a sleeping bag, a flashlight, food and water, a signaling mirror, a means of building a fire, and a two-way radio or cellular telephone.
For added protection, carry the following items on your snowmobile at all times:
- Spare Drive Belt • Winter Survival Kit
- Extra Set of Spark Plugs • Trail Map
• Tow Rope • Owner's Manual - Extra Oil • First Aid Kit
- Fuel Deicer • Tools
Operator Safety Rider Capacity
Your POLARIS snowmobile is designed for a single rider only. Do not carry a passenger.
Excessive Speed
WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather.
Always observe all state and local laws governing snowmobile operation and 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 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 over-drive your headlight beam. Always be able to bring your machine to a stop in the distance illuminated by the headlight.
SAFETY
Operator Safety Driver Awareness
Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wires on utility poles are also 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 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 verified that the ice is sufficiently thick to support the weight and moving force of the snowmobile, you and your cargo, together with any other vehicles in your party. Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Snowmobile operators assume all risk associated with ice conditions on frozen bodies of water.
When teaching inexperienced operators to ride, set up a predetermined course for practice. Make sure they know how to drive and control the snowmobile before allowing them to make longer trips. Teach them proper snowmobile courtesy, and enroll them in driver's training and safety courses.
Operator Safety Mountainous Terrain Riding
Mountainous terrain operation, even for experienced riders, can present conditions and situations that could result in serious injury or death. Please review all of the information about riding in mountainous terrain on the following pages of this manual.
WARNING! An avalanche can occur at any time, in any conditions and on any slope.
The avalanche information provided in this manual should be considered basic information and is not intended to replace your participation in an avalanche safety training course. After reviewing the avalanche information in this manual, be sure to participate in an avalanche safety training course before riding in mountainous terrain. The training course will provide more information as well as the opportunity to practice riding and using proper search and recovery techniques.
For more information, education, training courses and links to international resources, visit www.avalanche.org or scan the QR code with your smartphone or other device.
SAFETY
Operator Safety
Mountainous Terrain Riding
Get the Safety Gear
In addition to carrying a spare belt, spark plugs and tools on each snowmobile, each person in your riding group should wear the recommended snowmobile riding apparel and carry (on their person) the following survival items when riding in mountainous terrain:
• A digital avalanche beacon with new “fresh” alkaline batteries
• An avalanche probe
• A compact shovel and hand saw
• A backpack (preferably an avalanche air bag backpack)
• Emergency provisions, including the following items:
- Small first aid kit
- Extra pair of gloves
- Extra dry socks
- Tow rope, map, compass/GPS
- Lighter or waterproof matches
- Signal mirror and whistle
- Bottled water
- High calorie snack food
- Compact emergency blanket
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Collection of black and green fitness equipment including a 1+ device, backpack, and stationery (no visible text or symbols)Operator Safety Mountainous Terrain Riding Get to Know Your Safety Gear
Following the safety gear and apparel recommendations will increase your chances of survival if you encounter an avalanche or become stranded in the backcountry, but even experienced and properly-equipped snowmobilers, hikers and skiers perish in avalanches or succumb to hypothermia. Using a beacon or probe for the first time during an avalanche recovery operation, or not knowing how to deploy your avalanche air bag backpack during a slide, should be considered UNACCEPTABLE to you and all members of your riding group. It’s critical that you and all members of your riding group know how to use the safety gear.
While you may know how to use your gear, you may have to rely on your riding group to find you in an avalanche. Make sure they know how to use their gear.
- Dress in layers. Multiple layers of clothing provide the best barrier to cold and wind. Layers can be removed, but if you start out without enough layers, they cannot be added later. Avoid cotton materials, which will freeze if they get wet.
- Wear highly visible gear.
- Try on all gear and equipment to make sure it fits and doesn’t interfere with your riding capabilities. Place all survival aids in your backpack and wear the backpack at all times. Non-essential items can be stored on the snowmobile in an accessory bag.
- Read and follow the manufacturer's user and maintenance instructions for all gear. If you have questions about how your gear works, contact the manufacturer for more information.
- Practice using your beacons, shovels and probes with your riding group in real-world conditions wearing all of your gear. Have someone hide an active “transmitting” beacon by throwing it (not walking it) into a snowbank and timing your group’s search for it.
- Test deploying your gear. If you own an avalanche air bag backpack, check with the manufacturer's test deployment guidelines and bottle weight replacement specifications. Most air bag backpack manufacturers recommend testing the pack once a year so you know it works and feel comfortable with the bag and deployment time.
- Make sure your probe and shovel are in good condition and that you know how to assemble them.
SAFETY
Operator Safety
Mountainous Terrain Riding
Get Avalanche Safety Training
POLARIS recommends you and all members of your riding group participate in an avalanche safety course. Visit www.avalanche.org/education or scan the QR code for education and training resources.
Get the Forecast
Make a riding plan based on the current avalanche and weather forecast. It is important to remember that overnight weather conditions may have created unsafe riding terrain that was considered safe the day before. Visit www.avalanche.org or scan the QR code. Follow the page links to locate current avalanche reports and conditions for your area of operation.
Get the Picture
Slopes steeper than 30^ are more prone to avalanches, but any slope should be considered avalanche terrain, even small slopes with trees. Low-angle slopes are also avalanche terrain if they have steeper slopes above them.
NOTE: The 30^ slope graphic is for illustration purposes only. The risk of an avalanche is always present in mountainous terrain, regardless of slope angle.
Always look for the following warning signs of unstable snow. If you see or hear any of these signs, riding on or below any slope is dangerous and should be avoided:
- Recent avalanches
- A “whumpfing” sound under a snowpack
- Cracks across the top of a snowpack
• A recent heavy snowfall - Blowing snow
- Rain
- Rapid warming
Operator Safety Mountainous Terrain Riding Get Out of Harm's Way
- Before riding, always tell a responsible person (i.e. at the lodge or gas station) where your group is going.
- Never ride alone. Always ride in a small, manageable group. Riding in a large group makes it more difficult to track riders or find missing members.
- Go “one at a time”. Only one snowmobile at a time should cross, ascend or highmark a slope. Other riders should watch from a safe location until the previous rider exits the slope.
- Never park at the base of a slope or at the bottom of a gully or valley. When parking to take a break or watch other riders, park at the sides of the slope with the front of your snowmobile pointed away from the slope.
Get to Know Your Mountain Snowmobile
The following information pertains to a deep snow/mountain snowmobile. This type of snowmobile is longer and narrower and has a higher center of gravity when compared to a typical trail snowmobile. These features make riding the backcountry a safer and more enjoyable experience.
The mountain snowmobile is slower, has a larger turning radius and will overturn more easily than a trail snowmobile. The skis are designed to float and provide more lift than trail skis. The track features paddles that pack and shovel snow rather than dig in and grip the snowpack.
Because POLARIS mountain snowmobiles feature tall track paddles, the rear suspension rails and sliders will sit above the snowpack on a groomed trail. Always deploy the scratchers and limit high speed operation when trail riding. Do not rely on the engine temperature gauge to determine when to deploy rail scratchers. The rail sliders and track can overheat well before the engine temperature indicates the need for more cooling.
SAFETY
Operator Safety
Mountainous Terrain Riding
Get to Know Your Mountain Snowmobile
Always practice riding your mountain snowmobile in a safe, open, flat area before attempting your first ride in mountainous terrain. This is especially important for low-elevation riders who are not accustomed to riding a snowmobile designed for deep snow.
Do not ride in mountainous terrain until you are comfortable riding and controlling your snowmobile in deep snow.
- Practice turning, leaning and braking, both on the trail and off the trail. When you’re comfortable with these maneuvers, practice more advanced maneuvers in deep flat snow.
- Learn techniques from more experienced riders.
- Practice placing your feet in different locations on the floorboards to learn where your balance point is while performing turns and other maneuvers.
- Practice traversing through deep snow, which is when you will often need to steer by leaning your body weight in the desired direction while turning the skis slightly in the opposite direction.
- Practice using proper throttle control to maintain vehicle momentum and adequate track speed in deep snow. Everyone gets stuck at some point in time. If you know your snowmobile is becoming stuck, try to turn downhill as much as you can before the snowmobile comes to a stop.
Operator Safety Mountainous Terrain Riding Avalanche Awareness
Avalanches are a matter of timing. A steep slope can be safe one day, but unsafe the next day due to changing weather and wind conditions.
- Always review the user instructions provided with your safety equipment and follow the recommendations for maintenance, testing and use. Always test your safety equipment to ensure it works properly before riding in mountainous terrain.
• Always store your survival gear in your backpack and wear the backpack. Do not store your survival gear on the snowmobile.
• Always research current avalanche conditions in your area of operation before riding. Check with local law enforcement, resort or lodging personnel, gas station attendants and other riders to learn about current conditions and any advisories in the area. - Read and understand the avalanche danger scale. See page 22. Pay attention to any danger level warnings issued for your area of operation.
- Always remain alert while riding in mountainous terrain. Be aware of snowpack conditions above you as you ride. Avalanches can occur at any time regardless of current condition reports.
SAFETY
Operator Safety
Mountainous Terrain Riding
| North American Public Avalanche Danger ScaleAvalanche danger is determined by the likelihood, size and distribution of avalanches. | ||||
| Danger Level | Travel Advice Likelihood of Avalanches | Avalanche Size and Distribution | ||
| 5 Extreme |  | Avoid all avalanche terrain. | Natural and human-triggered avalanches certain. | Large to very large avalanches in many areas. |
| 4 High |  | Very dangerous avalanche conditions. Travel in avalanche terrain not recommended. | Natural avalanches likely; human-triggered avalanches very likely. | Large avalanches in many areas; or very large avalanches in specific areas. |
| 3 Considerable |  | Dangerous avalanche conditions. Careful snowpack evaluation, cautious route-finding and conservative decision-making essential. | Natural avalanches possible; human-triggered avalanches likely. | Small avalanches in many areas; or large avalanches in specific areas; or very large avalanches in isolated areas. |
| 2 Moderate |  | Heightened avalanche conditions on specific terrain features. Evaluate snow and terrain carefully; identify features of concern. | Natural avalanches unlikely; human-triggered avalanches possible. | Small avalanches in specific areas; or large avalanches in isolated areas. |
| 1 Low |  | Generally safe avalanche conditions. Watch for unstable snow on isolated terrain features. | Natural and human-triggered avalanches unlikely. | Small avalanches in isolated areas or extreme terrain. |
| Safe backcountry travel requires training and experience. You control your own risk by choosing where, when and how you travel. | ||||
Operator Safety Ice and Snow Build-up
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 and snow build-up that may be obstructing the steering linkage.
Driving on Slippery Surfaces
WARNING! Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard-packed snow reduces steering and braking control, which may result in loss of control and serious injury or death. Slow down and use extra caution when operating on slippery surfaces.
Inadequate Snow Conditions
Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile.
NOTICE: Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine.
WARNING! Inadequate cooling and lubrication will lead to overheating of the slide rail and track, causing premature wear, damage and failure, which can result in serious injury. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating for prolonged periods on ice, hard-packed surfaces or roads.
Operating in Deep Snow
If the machine becomes stuck in snow, clear the running board area of snow, then step 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.
SAFETY
Operator Safety Driving Downhill
When riding downhill, shift your weight to the rear of the machine 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 machine and keep it from rolling freely downhill.
WARNING! When driving on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, which may result in brake failure. Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system. This condition may lead to a sudden loss of brakes and/or fire and may result in serious injury or death.
Driving in Hilly Terrain
WARNING! Climbing a hill or crossing the face of a slope may result in loss of balance and snowmobile rollover, causing serious injury or death. Use caution and good judgement when driving in hilly terrain.
Use extra caution when operating in hilly terrain. 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 machine to maintain proper balance and avoid possible roll-over.
Slow down when reaching the crest of a hill. Be prepared to react to obstacles, sharp drops or other people or vehicles that may be on the other side of the hill.
If you're unable to continue up a hill, turn the snowmobile 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 the engine and set the parking brake (if equipped). Keeping away from the downhill side of the snowmobile, pull the rear of the snowmobile around and point the front end and skis downhill. Remount the snowmobile, restart the engine, release the parking brake, and descend the hill carefully.
Operator Safety Drive Belt
Do not operate the engine with the drive belt removed.
CAUTION! Operation of the engine with the belt removed may result in personal injury or damage to the engine.
Any servicing that requires operation without a belt must be performed by your dealer.
Intake Silencer
Do not operate the engine with the intake silencer or filter removed.
NOTICE: Damage to the engine may occur if the intake silencer or filter are removed.
Clutches
Do not attempt to service the clutches.
All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time, especially 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 the machine into motion, but always operate within safety limits.
Maneuverability
While much control and maneuverability is achieved through the steering system and skis, maximum control is achieved by the shifting of your body weight. Maneuverability will change for lighter operators or machines designed to carry a load.
SAFETY
Operator Safety Driving Responsibly
Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the machine and with what it will and won't do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
- A snowmobile depends on the rider's body position for proper balance in executing turns, traversing hills, etc. Always start on a smooth, level area to begin building your operating experience.
- Before allowing someone else to use your snowmobile, know the extent of their operating skills. Check to see if they've taken a snowmobile safety course and have an operator's certificate. For their protection, 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. 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 protection under normal riding conditions. Your snowmobile is not intended for this kind of use.
- Be courteous to oncoming traffic by dimming your headlights and reducing your speed.
- When traveling in a group of snowmobiles, don't tailgate (follow too closely). Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris. Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions. Be aware of any snowmobile traffic around your vehicle. Drive defensively to avoid accidents.
Operator Safety Windchill/Temperature Charts
The following information is provided to help you determine when temperatures become dangerous for riding.
Safety Labels and Locations
Warning labels have been placed on the snowmobile for your protection. Read and follow the instructions of the labels and other warnings on the snowmobile carefully. If any of the labels depicted in this manual differ from the labels on your snowmobile, always read and follow the instructions of the labels on the snowmobile.
If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
Clutch Cover Warning
This warning label is found under the hood on the clutch cover:
WARNING
Do not operate engine with hood open.
Do not attempt adjustment with engine running.
Do not operate engine with this guard removed.
Never run engine with drive belt removed.
Never service clutches yourself -- see your dealer.
7079297
Pressure Cap Warning
This warning label is found on the pressure cap of applicable liquid cooled models:
Do not open hot. Test or replace when changing coolant. Press down and turn to release cap. 13 PSI
7170063
No Passenger Warning
Snowmobiles designed for a single rider only have the NO PASSENGER warning label on the lower center console:
WARNING
This vehicle is designed for operator only. NO PASSENGER
7172575
Track Warning
The track warning label is at the rear of the tunnel:
WARNING
Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back can result in severe injury or death.
7172519
Safety Labels and Locations Operation Warning
The operation warning label is located on the console.
WARNING
- To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, contact a POLARIS dealer for a replacement.
- This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control. Reduce speed and use extreme caution when operating in unfamiliar terrain.
- Excessive speed, especially at night or with limited visibility, can result in insufficient time for you to react to terrain changes, to avoid unexpected obstacles, or to stop safely.
- Never consume alcohol or drugs before or while operating this vehicle.
- In an emergency, push down the Auxiliary Shut-Off Switch, located on the top of the throttle control assembly, to stop the engine. Then pull the brake lever to stop.
- Always wear an approved 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 approved models only), reduce speed and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle.
- When operating on hard-packed snow, ice, or when crossing roads, steering and braking ability are greatly reduced. Reduce speed and allow extra space to turn or stop.
- To maintain vehicle control on ice or hard-packed surfaces, you should have a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products.
- Repeated stops from high speed may cause fading or sudden loss of braking ability.
- Parking brake may relax when used for long periods. Do not leave brake engaged for more than five minutes.
- Before starting engine, check throttle, brake, and steering for proper operation. Make sure hood is latched. Be seated and in position to control the vehicle.
7173374
SAFETY Safety Labels and Locations
Competition ONLY Warning
This warning label is located under the hood on the upper left console.
WARNING
This snowmobile is a competition model only and is not manufactured for, nor should it be used on public land or trails. The use of this snowmobile should be limited to participation in sanctioned competition events upon a closed course. This snowmobile should NOT be used for general off-trail recreational riding. This snowmobile is intended for experienced racers only, and NOT for beginners.
7178397
FEATURES
- Headlight Dimmer Switch
- Ignition Switch/Tether Switch
- Master Cylinder
- Handlebar Pad
- Engine Stop Switch
- Throttle Control
- Recoil Starter Handle
- Hold Down Straps
-
Fuel Filler Cap
-
Choke Control
- Hand/Thumbwarmer Switch
- Brake Lever
- Parking Brake Lock
- DRAGON Ignition System Switch
- Tachometer
- Temperature Light
FEATURES
POLARIS DRAGON Ignition System
Your snowmobile is equipped with an ignition system feature that improves competition performance by increasing exhaust system temperature. The DRAGON Ignition System provides maximum “holeshot” performance for racing applications.
WARNING! DRAGON mode increases the exhaust system temperature and causes engine misfire and backfire. Flammable materials and vapors may ignite and result in fire and explosion, which may cause serious injury, death or property damage. Read the Owner's Manual. Always follow all instructions and warnings.
DRAGON Mode Facts
- The DRAGON Ignition System is intended for competition use on closed courses by experienced riders only.
- There is no benefit to using DRAGON 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 the exhaust system within 5 to 20 seconds, depending upon the initial temperature of the exhaust system.
- Two different sounds may be heard when using DRAGON mode. One sound is an erratic misfire that may be heard when the exhaust system is heating up. The other sound is a consistent misfire (with a slight rise in engine RPM) when the exhaust system is at target operating temperature.
- DRAGON mode maintains the engine speed between 4500 and 5100 RPM.
- Be sure that the clutch engages at 5300 RPM or above to prevent forward creep of the vehicle. See your dealer if the clutch needs adjustment.
- Please refer to the POLARIS jetting chart and use the recommended jet for current temperatures as this system is sensitive to jet changes.
FEATURES
POLARIS DRAGON Ignition System
- Warm up the engine and track.
- When staged at the starting line, depress and hold the DRAGON button on the left handlebar (1).
- Slowly advance the throttle to the wide-open position while keeping the button depressed.
- Release the button when the start flag drops.
TIP: The vehicle will launch forward at wide-open throttle.
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Close-up of a mechanical component with hoses and a dial, no visible text or symbolsTHE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS)
Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments.
Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. The machine should be methodically tested, one change at a time, under the same conditions (trail and snow conditions, vehicle speed, riding position, etc.) after each adjustment until the best ride is achieved.
IFS Components
- Skis
- Front shocks and springs
- Rod ends
- Control arms
IFS Adjustment Options
- Front shock spring preload
- Optional springs
- Optional shock valving (Walker/Evans shocks)
• High/Low Compression damping - Rebound damping
- Toe (ski alignment)
THE PERFECT FIT
Front Suspension Adjustments Shock Spring Preload
Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment.
To change front shock spring preload, grasp the spring and rotate it.
Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension. Never exceed one inch of preload 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 holding the spring between the retainer on the top of the shock and the threaded spring preload adjuster nut on the shock body. Failure to do so could cause the retainer to fall off when the suspension is fully extended.
TIP: Not all models have shocks with thread-adjustable spring preload. See your dealer for more information.
NOTICE: On some models equipped with a plastic adjuster nut, the nut will break if it is unscrewed from the threaded body. Do not force the nut if resistance suddenly increases while you're turning it.
THE PERFECT FIT
Front Suspension Adjustments Shock Valving (Walker/Evans Shocks)
These shocks can be revalved if spring preload alone isn't sufficient and further adjustment is desired 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.
Compression Damping
High Compression Damping Force Adjustment
Increase the high compression damping force by turning the adjuster clockwise to increase the stiffness.
Decrease the high compression damping force by turning the adjuster counter-clockwise to increase the softness.
The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 22 clicks out from the maximum position.
| Standard Position | |
| High speed adjuster 14 clicks out from fully turned in position |
CAUTION! Do not turn the adjuster past the minimum or maximum adjustment. The adjuster may be damaged.
THE PERFECT FIT
Front Suspension Adjustments
Compression Damping
Low Compression Damping Force Adjustment
Increase the low compression damping force by turning the adjuster clockwise to increase the stiffness.
Decrease the low compression damping force by turning the adjuster counter-clockwise to increase the softness.
The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 28 clicks out from the maximum position.
Adjuster
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Close-up of a mechanical component with a central hexagonal bolt and threaded shaft (no visible text or symbols)Softer
| Standard Position | |
| Low speed adjuster 14 clicks out from fully turned in position |
CAUTION! Do not turn the adjuster past the minimum or maximum adjustment. The adjuster may be damaged.
THE PERFECT FIT Front Suspension Adjustments
Rebound Damping Force Adjustment
Increase the rebound damping force by turning the adjuster clockwise to increase the stiffness.
Decrease the rebound damping force by turning the adjuster counter-clockwise to increase the softness.
The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 16 clicks out from the maximum position.
| Standard Position | |
| Rebound adjuster 4 clicks | out from fully turned in position |
CAUTION! Do not turn the adjuster past the minimum or maximum adjustment. The adjuster may be damaged.
Front Springs
For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. See your POLARIS dealer for more information.
THE PERFECT FIT
Rear Suspension Adjustments
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. Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action.
Each rear suspension can be adjusted to suit rider preference and deliver the best performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail. A suspension set up for trail riding would bottom out harshly on a snow-cross course.
Make adjustments to one area at a time so you can evaluate the change. For further assistance, see your dealer.
Suspension Performance Tips
- Rider weight usually determines the position at which the spring preload should be set. However, this may vary with riding style. 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.
- When riding on ice or hard-packed snow, adding a set of bogie wheels to the rail may enhance the machine's performance. Bogie wheel kits are available from your dealer.
TIP: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components. Grease rear suspension pivots before adjusting the rear suspension. Refer to Suspension Maintenance beginning on page 98.
Track Tension
Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Refer to the track tension maintenance section beginning on page 92.
THE PERFECT FIT
Rear Suspension Adjustments
Torsion Spring Tension
To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information.
Cam Adjustments
Soft Tension: Move the long end of the cam to the front.
Medium Tension: Move the short end of the cam upward.
Firm Tension: Move the long end of the cam upward.
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Simple line drawing of a mechanical clamp or bracket with a circular ring and a hex nut (no text or symbols)Soft Tension
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Simple line drawing of a mechanical clamp or bracket with a circular ring and a bolt (no text or symbols)Medium Tension
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Simple line drawing of a mechanical clamp or bracket with a circular ring and a hexagonal nut (no text or symbols)Firm Tension
THE PERFECT FIT
Rear Suspension Adjustments Compression Damping High Compression Damping Force Adjustment
Increase the high compression damping force by turning the adjuster clockwise to increase the stiffness.
Decrease the high compression damping force by turning the adjuster counter-clockwise to increase the softness.
The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 22 clicks out from the maximum position.
| Standard Position | |
| Front Track suspension high speed adjuster | 14 clicks out from fully turned in position |
| Rear Track suspension high speed adjuster | 14 clicks out from fully turned in position |
CAUTION! Do not turn the adjuster past the minimum or maximum adjustment. The adjuster may be damaged.
Front Track Suspension
Rear Track Suspension
THE PERFECT FIT Rear Suspension Adjustments Compression Damping Low Compression Damping Force Adjustment
Increase the low compression damping force by turning the adjuster clockwise to increase the stiffness.
Decrease the low compression damping force by turning the adjuster counter-clockwise to increase the softness.
The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 28 clicks out from the maximum position.
| Standard Position | |
| Front Track suspension low speed adjuster | 14 clicks out from fully turned in position |
| Rear Track suspension low speed adjuster | 10 clicks out from fully turned in position |
CAUTION! Do not turn the adjuster past the minimum or maximum adjustment. The adjuster may be damaged.
Front Track Suspension
Rear Track Suspension
THE PERFECT FIT
Rear Suspension Adjustments
Rebound Damping Force Adjustment (Rear track suspension only)
Increase the rebound damping force by turning the adjuster clockwise to increase the stiffness.
Decrease the rebound damping force by turning the adjuster counter-clockwise to increase the softness.
The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 16 clicks out from the maximum position.
| Standard Position | |
| Rear track Rebound adjuster | 5 clicks out from fully turned in position |
CAUTION! Do not turn the adjuster past the minimum or maximum adjustment. The adjuster may be damaged.
Suspension Coupling
On all POLARIS snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other. Rear suspension coupling links the movement of the front and rear torque arms to each other. There are two types of rear suspension coupling.
THE PERFECT FIT
Rear Suspension Adjustments 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 independence between the movement of the front torque arm and the rear torque arm.
When hitting a bump, the front torque arm starts to compress. The FRSS links that movement to the rear torque arm, causing it to compress and raise the rear suspension up as one, allowing the suspension to hit the bump only once and eliminating kickback. Your FRSS is preset at the factory.
Rear Rear Scissor Stop (RRSS)
The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm.
Adjusting the RRSS either allows more weight to transfer to the rear for more traction, or allows less weight to transfer to the rear, resulting in improved cornering performance. An adjustment dot is located on the RRSS. This dot is on the longest end of the scissor stop.
Rear Rear Scissor Stop - Attributes
Moving the RRSS to a higher position, or forward hole, will have the following effects on the suspension:
- Reduced weight transfer.
- Improved chatter bump ride.
- Improved cornering performance.
THE PERFECT FIT
Rear Suspension Adjustments Weight Transfer During Acceleration
The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop. Use the scissor stop tool located in your tool kit to make the adjustments.
To decrease weight transfer under acceleration (for improved cornering), rotate the stop to a higher position.
To increase weight transfer or ski lift during acceleration, 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.
Medium Position - This setting is the production setting and will provide the best overall trail riding.
High Position - This setting will decrease weight transfer.
Rearward Upper Position
(optional hole location) - This setting will increase weight transfer.
TIP: Your dealer can help you with initial setup and additional setup instructions to help you achieve your optimum ride.
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Technical line drawing of a mechanical clamp or bracket component (no text or symbols)Low Position
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Technical line drawing of a mechanical component with bolts and a curved handle (no text or symbols)Medium Position
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Technical line drawing of a mechanical clamp or bracket component (no text or symbols)High Position
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Technical line drawing of a mechanical component with bolts and a curved handle (no text or symbols)Rearward Upper Position
THE PERFECT FIT Handlebar Adjustments Handlebar Position
- Loosen the four bottom adjuster block bolts. If necessary, pry the blocks apart with a screwdriver.
- Adjust the handlebar forward or rearward to the desired position. Tighten the bolts.
Handlebar Angle
- Loosen the four top adjuster block bolts. If necessary, pry the blocks apart with a screwdriver.
- Adjust the handlebar forward or rearward to the desired angle. Be sure handlebars, 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
Loosen top bolts to adjust handlebar angle
Loosen bottom bolts to adjust handlebar position
- Tighten 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 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.
THE PERFECT FIT
Traction Products Studs
Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products.
Use only POLARIS traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-POLARIS traction products.
See your dealer about installing studs and/or carbides.
NOTICE: 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 ability may be reduced on hard-packed snow or ice.
When studded tracks are used, increased wear to the brake pads will result from increased braking. Extended-wear brake pad kits are available. See your dealer.
NOTICE: Studding the outer edges of the track will cause cooling system damage. Install studs only in center belt of track. Stud point cannot protrude more than 0.375 in. (0.95 cm) above the lug tip when installed.
Traction Products Carbide Skags
A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control. See page 97.
If your machine has carbide skags, it may be necessary to add track studs to maintain proper vehicle control. Maintain a proper balance between the number of studs and the length of carbide on the skags (the more studs you use, the longer the carbide on the skags should be). See your dealer's track studding chart.
PRE-RIDE INSPECTIONS
Pre-Ride Checklist
Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages.
| Item See Page | |
| Drive Belt Condition 87 | |
| Steering System 52 | |
| Recoil Rope 53 | |
| Coolant Level 76 | |
| Parking Brake Lock/Brake Lever/Brake System 50, 51, 80 | |
| Auxiliary Shut-Off Switch (Engine Stop Switch) 54 | |
| Tether Switch/Strap 54 | |
| Taillight/Brake Light/Headlight 54 | |
| Suspension Mounting Bolts -- | |
| Skags (Wear Bars) 97 | |
| Ski Saddle and Spindle Bolts -- | |
| Hood Straps/Latches | 53 |
| Seat Latches (if equipped) | 53 |
| Throttle Lever | 49 |
| Rear Wheel Idler Bolts | 93 |
| Track Alignment/Condition | 52, 94 |
| Rail Slide Condition | 97 |
| Chaincase Oil Level | 71 |
PRE-RIDE INSPECTIONS
Before Starting the Engine
Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation.
WARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death. Never start the engine without checking all vehicle components to be sure of proper 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.
Throttle Lever
The throttle and brake are the primary controls of your snowmobile. Always make sure both are functioning properly.
Squeeze the throttle lever to make sure it compresses evenly and smoothly. When released, the lever should immediately return to the idle position without binding or hesitation. If the throttle does not function smoothly, or if you discover excessive lever freeplay, DO NOT start the engine. Have the throttle serviced immediately.
PRE-RIDE INSPECTIONS Before Starting the Engine Brakes
Always check the following items for proper operation before starting the engine.
Brake Lever Travel
Squeeze the brake lever. It should move no closer to the handgrip than 1/2" (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 82 or see your dealer for service.
Lever Feel
If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See page 81.
WARNING! Continued use of "spongy" brakes may cause a complete loss of brakes, which could result in serious injury or death. Always have the brakes serviced at the first sign of sponginess.
Brake Fluid
Check the brake fluid in the master cylinder before each ride.
View the brake fluid level through the sight glass on the top of the master cylinder. The eye will appear dark when the fluid level is full. If the sight glass is any color other than black, add brake fluid. See page 81.
PRE-RIDE INSPECTIONS
Before Starting the Engine Parking Brake Lever Lock
Use the parking brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less.
Lock Engagement
To engage the lock, squeeze the brake lever tightly and push forward on the lock. Hold the lock forward while releasing the brake lever.
TIP: If the brake lever is squeezed tightly enough, the lock will move freely into place. Do not force the lock or it may break.
The brake light will illuminate if the parking brake lever lock is set while the engine is running. It will also illuminate when the service brake is in use. If the parking brake light does not come on when the parking brake or service brake is in use, have it serviced by your dealer.
Lock Release
To release the lock, squeeze the brake lever tightly. The lock will return to the unlocked position.
WARNING! If the parking brake lever lock is partially or entirely engaged while riding, the brakes may overheat, resulting in brake damage. In extreme cases it could cause a fire, which could result in serious injury or death. Always ensure that the lever lock is completely disengaged before operating the snowmobile.
PRE-RIDE INSPECTIONS
Before Starting the Engine
Steering System
WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, which could cause loss of control 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 and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated.
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. Always inspect the track for damage before using the vehicle.
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.
TIP: Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty.
PRE-RIDE INSPECTIONS
Before Starting the Engine Hood Latches
The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmobile.
Seat Latches
If your snowmobile is equipped with a removable seat, ensure that the seat latches are securely in place before every use of the snowmobile.
Recoil Rope
Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your POLARIS dealer for replacement.
PRE-RIDE INSPECTIONS Start the Engine and Check
Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Before Starting the Engine beginning on page 49.
Engine Stop Switch
Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting.
Tether Switch
Remove the tether from the switch to make sure the engine stops immediately.
Lighting
Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating.
Mirrors (if equipped)
Adjust the mirrors so they can be used to their full advantage.
Operating Area
Before driving away, check your surroundings. Be aware of obstacles and make sure bystanders are a safe distance from the machine.
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel outdoors or in a well-ventilated area.
• Always turn off the engine before refueling.
- Do not overfill the tank. Do not fill the tank neck.
- Do not smoke or allow open flames or 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 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.
- Turn the fuel valve off whenever the snowmobile is stored or parked.
WARNING
The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.
OPERATION Break-In Period Engine Break-In
Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine.
Always premix the initial fuel and future fuel. See page 57.
Excessive heat build-up during the first three 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.
NOTICE: Use of any lubricants other than those recommended by POLARIS may cause serious engine damage. We recommend the use of POLARIS lubricants for your vehicle.
Drive with extra caution during the break-in period. Perform regular checks on fluid levels, lines, and all other important areas of the machine.
Break-In Period
Engine Break-In
Oil Recommendations
The only source of engine lubrication for this engine comes from lubrication added to the fuel. Always premix the fuel.
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. See page 106 for the part numbers of POLARIS products.
| Recommended Oil | |
| 600 IQ Racer VES | RACE 2-Cycle Engine Oil |
Fuel Recommendations
Always use premium non-oxygenated (92 octane) fuel in this snowmobile. Always premix the fuel.
NOTICE: Using fuels with a lower than recommended octane or operating with obstructed fuel systems will result in serious and costly engine damage. Always use the recommended fuels for your machine.
Fuel Premix
| Initial Tank of Fuel | ||
| Fuel Oil Ratio | ||
| 3.5 gal (13.2 l) 16 oz. | (473 ml) 28:1 | |
| Future Fuel | ||
| Fuel Oil Ratio | ||
| 3.5 gal (13.2 l) 14 oz. | (414 ml) 32:1 | |
OPERATION Break-In Period Engine Break-In
Fuel System Deicers
When using non-oxygenated fuel, use an 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 containing methanol.
POLARIS also recommends the use of Carbon Clean. See page 106 for 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 period for a new drive belt is 30 miles (48 km). During this time, vary the throttle position under 50% and limit full throttle use.
New drive belts should be washed with warm, soapy water and allowed to air dry prior to use.
Always take time to warm up the belt and driveline prior to operating the snowmobile. Free the track and skis from the ground before engaging throttle.
Starting the Engine
CAUTION! To avoid personal injury and/or engine damage, do not operate the recoil pull-rope starter while the engine is running.
Starting a Cold Engine
Do not depress the throttle until the engine starts.
- Attach the tether cord to the tether switch.
- Pull the kill switch (shut-off switch) up to RUN.
- Flip the choke toggle to FULL CHOKE.
- Grasp the starter handle and pull slowly until the recoil engages, then pull abruptly to start the engine.
NOTICE: Don't pull the starter rope to the fully extended position and don't allow it to snap back into the housing. Damage may result.
- After the engine starts, flip the choke toggle 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 damage. Allow the engine to warm up for several minutes before operating the vehicle. If cold drive-away is attempted, the engine RPM may stumble slightly to protect the engine.
- Warm up the engine before operating.
Starting a Warm Engine
- Attach the tether cord to the tether switch.
- Pull the kill switch (shut-off switch) up to RUN.
- Grasp the starter handle and pull slowly until the recoil engages; then pull abruptly to start the engine.
- If the engine does not start on the first pull, slightly depress the throttle with your left hand (no more than 1/4 inch open) and pull the rope with your right hand. When the engine starts, immediately release the throttle.
OPERATION Emergency Stopping
The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 54 for more information about the engine stop switch.
| SYSTEM WHAT IT DOES | THROTTLE CONDITION |
| Brake Slows jackshaft All | |
| Choke Floods engine Half throttle or less | |
| Engine Stop Switch Interrupts ignition circuit All | |
| Tether Switch Interrupts ignition circuit All |
WARNING! Excessive or repetitive use of brakes for high speed stops will cause an overheated brake system. This overheated condition could cause sudden loss of brakes and/or 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.
Engine Stop Switch
Push the engine stop switch down to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting.
Track Warm-Up
WARNING
A loose track or flying debris could cause serious injury or death. Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Be sure the rear support is stable.
WARNING
Use of traction products such as studs, ice growers, etc. will increase the possibility of track damage and/or failure. This could cause loss of control, resulting in serious injury or death. Always inspect for track damage before operating the snowmobile.
Follow these steps to ensure proper warm-up of the engine, drive train and track.
-
Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper. The track should be about 4 inches (10 cm) off the ground.
-
Start the engine and allow it to warm up two to three minutes.
-
Depress the throttle abruptly and allow the track to rotate several revolutions.
TIP: It will take longer to warm up the track sufficiently during colder outdoor temperatures.
-
Release the throttle, apply the brakes, shut off the engine and lower the machine to the ground.
-
Grasp the skis by their front loops and move them from side to side to loosen snow and ice.
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Line drawing of a mechanical device with lever and base plate (no text or symbols)Slide Rail and Track Cooling
NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or roads.
OPERATION
Carburetion
Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance.
A lean mixture may be caused by things like fuel line restrictions, foreign matter in the carburetor or clogged fuel filters. A rich mixture may be caused by snow build-up on the pre-filter in the air intake system. Either condition may be caused by improper carburetor adjustment.
CAUTION! Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage. Always have your POLARIS dealer perform any carburetor adjustments.
Jetting Guidelines
Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense.
The carburetors are calibrated for an altitude of 0-2000 ft. (0-600 m) and ambient temperatures from +15° to +35° F. (-9° to +2° C.). Carburetors must be re-calibrated if the snowmobile is operated outside this production temperature and/or altitude range. The main jet installed in production is not correct for all altitudes and/or temperatures. See page 75 for more information.
NOTICE: A main jet that's too small will cause a lean operating condition and may cause serious engine damage. Jet the carburetors carefully for elevation and temperature according to the jetting charts for your vehicle. See page 105.
TIP: Always ensure that the correct jets are installed in the machine for the geographical area of operation. Be very careful when jetting down in warm weather. As the weather turns colder it will be necessary to re-jet upward to prevent engine damage. When selecting the proper main jet always use the lowest elevation and temperature that is likely to be encountered.
OPERATION
Daily Storage
At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 inches (10 cm) off the ground.
Cover the machine with an appropriate cover.
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Line drawing of a mechanical device with a ladder and frame (no text or symbols)Towing
For your safety, do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions.
WARNING! Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in serious injury or death. DO NOT tow toboggans, sleds, saucers, or any type 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 to maintain control of the snowmobile.
If the snowmobile becomes inoperable and must be towed, and if it isn't possible to use a rigid tow bar, attach the tow rope to the ski spindles (not to the ski loops) to prevent damage to the steering components. Remove the drive belt before towing, and have someone ride on the towed snowmobile to operate the brake and steering when necessary.
NOTICE: Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system. Always remove the drive belt from a disabled snowmobile before towing.
MAINTENANCE Emission Control Information
Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile.
Emission Control Label
Your snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory-installed emissions information hang-tag. These items are required by U.S. Environmental Protection Agency regulations. The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover. The ECI label should not be removed, even after you purchase the snowmobile. You may remove the factory-installed emissions information hang-tag, which 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 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. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups.
Owner's Responsibilities
Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed. POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary.
Non-ionizing Radiation
This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.
MAINTENANCE
POLARIS Recommended Maintenance Program
To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 121.
The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1000 miles (1600 km). These inspections should be performed by a qualified service technician. For continued optimum performance and component life, continue maintenance checks at 1000 mile (1600 km) intervals.
All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, become the responsibility of the registered owner. If, during the course of the warranty period, part failures occur as a result of owner neglect in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner.
Personal safety is critical when attempting to service or make adjustments to your snowmobile. If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfortable performing these tasks yourself, contact an authorized POLARIS dealer for service.
NOTICE: Hot components can cause damage to plastic. Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection.
MAINTENANCE
Periodic Maintenance Interval Table
The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine POLARIS parts, available from your POLARIS dealer.
| Item See | Page | Frequency | ||||
| 150 mi.(240 km) | 500 mi.(800 km) | 1000 mi.(1600 km) | 2000 mi.(3200 km) | Pre-Season | ||
| CLUTCH | ||||||
| Clutch Alignment Offset(without belt) | 86 I | I | I | |||
| Drive Belt Condition 87 I | I | I | I | |||
| Clutches 86 C C | C | |||||
| Belt Tension -- I | I | I | I | |||
| Clutch Sheaves 86 I | I | I | I | |||
| ENGINE/COOLING | ||||||
| Engine Mounts | -- I | I | I | I | ||
| Recoil Rope -- I | I | I | I | |||
| Engine Mounting Plate | -- I | I | I | |||
| Engine Torque Stop | 89 I | I | I | I | ||
| Cylinder Head Bolts | -- I | I | I | |||
| Cylinder Base Nuts | -- | I | I | I | I | |
| Ignition Timing BTDC | -- I | I | I | |||
| VES System | -- C | C | C | I | ||
| Coolant Level | 76 | I | I | I | I | I |
| Coolant Change -- | R - Every 5 years | |||||
| Coolant Hose | -- I | I | I | I | ||
| Heat Exchangers | 78 | I | I | I | I | I |
| Coolant Circulation | -- I | I | I | |||
| Coolant Leaks | -- I | I | I | I | ||
| Spark Plug Condition | 72 | I | I | I | R | I |
| Exhaust Pipe | 79 | I | I | |||
| Exhaust Retaining Springs | 79 I | I | I | I | ||
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate
MAINTENANCE
Periodic Maintenance Interval Table
| Item See | Page | Frequency | ||||
| 150 mi.(240 km) | 500 mi.(800 km) | 1000 mi.(1600 km) | 2000 mi.(3200 km) | Pre-Season | ||
| BRAKES | ||||||
| Hose Routing -- I | I | I | I | |||
| Hose Condition -- I | I | I | I | |||
| Fluid Leaks -- I | I | I | I | |||
| Brake Pads 80 I | I | I | I | |||
| Brake Disc -- I | I | I | I | |||
| Parking Brakes 51 I | I | I | I | |||
| Brake System 50, 80 I | ||||||
| Brake Fluid 81 I | ||||||
| FUEL MANAGEMENT | ||||||
| Pilot Air Screws -- I | I | I | ||||
| Carburetor(synchronize) | 75 I | I | I | |||
| Idle RPM -- I | I | I | ||||
| Throttle Lever 49 | I | I | I | I | I | |
| Throttle Cable | 70 | L | L | L | ||
| Choke Cable | 70 | L | L | L | ||
| Choke | 71 I | I | I | |||
| Vent Lines | -- | I | I | I | I | I |
| Throttle Position Sensor | -- I | I | I | |||
| Fuel Lines 75 I | I | I | I | |||
| Fuel Filter | 75 | R | R | |||
| Air Box | -- | I | I | I | I | I |
| ELECTRICAL | ||||||
| Auxiliary Shut-Off Switch | 54 | I | I | I | I | I |
| Taillight | 54 | I | I | I | I | I |
| Brake Light 54 I | I | I | I | I | ||
| Headlight | 54 | I | I | I | I | I |
MAINTENANCE
Periodic Maintenance Interval Table
| Item See | Page | Frequency | ||||
| 150 mi. (240 km) | 500 mi. (800 km) | 1000 mi. (1600 km) | 2000 mi. (3200 km) | Pre-Season | ||
| CHASSIS | ||||||
| Ski Toe Alignment -- I | I | I | ||||
| Suspension Mounting Bolts | -- I | I | I | I | I | |
| Steering Fasteners -- I | I | I | I | C | ||
| Rear Suspension Fasteners | -- I | I | I | I | I | |
| Suspension Shock Oil -- I | I | I | I | |||
| Cooling Fins and Shroud | -- I | I | I | I | ||
| Skags (Wear Bars) 97 I | I | I | I | |||
| Ski Saddle/Spindle Bolts | -- I | I | I | I | I | |
| Steering Post U-Joint | 69 | L | L | L | L | |
| Steering Arm(s) -- | L | L | L | L | ||
| Upper / Lower Steering Post Support Bracket | -- | L | L | L | L | |
| Drive Chain Tension | 79 I | I | I | I | I | |
| Hood Latches/Straps | 53 I | I | I | I | I | |
| Rear Wheel Idler Bolts | 93 I | I | I | I | I | |
| Idler Bolt Jam Nut | 93 I | I | I | I | I | |
| Radius Rod Bushings | -- | I | ||||
| Rear Suspension Pivot Shafts | 69 | L | L | L | ||
| Handlebar Centering -- | I | |||||
| Tether Switch and Strap | 54 I | I | I | I | I | |
| Track Alignment | 94 I | I | I | I | I | |
| Track Tension | 92 I | I | I | I | I | |
| Front Limiter Strap | -- I | I | I | I | I | |
| Rail Slide Condition | 97 | I | ||||
| Chaincase Oil | 71 I | I | I | R | I | |
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate
MAINTENANCE
Lubrication
Lubrication points are indicated in the illustrations below.
Front Suspension
Lubricate the steering post U-joint at the intervals outlined in the maintenance charts beginning on page 65.
natural_image
Close-up of a mechanical assembly with a tool and bracket, no visible text or symbolsRear Suspension
Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 65 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 suspension. For more information about suspension lubrication and adjustments, see your POLARIS dealer.
MAINTENANCE
Lubrication
Throttle Cable
Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown.
Choke and Choke Cable
Lubricate the choke slide and cables lightly with oil or grease. Before turning the engine off, operate the choke intermittently to draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen.
Lubrication Chaincase Oil
Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 65. Change the chaincase oil after the first 500 miles (800 km), then every 2000 miles (3200 km) or seasonally.
Maintain the 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 106 for the part numbers of POLARIS products.
Oil Check
- Position the vehicle on a level surface.
- Remove the dipstick (1) and view the oil level on the dipstick.
- Add the recommended oil as needed. Do not overfill.
- Clean the magnetic plug (2).
- Reinstall the dipstick.
MAINTENANCE
Spark Plugs
A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization.
- Use recommended spark plugs with the proper gap.
- Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).
• Always carry spare spark plugs.
NOTICE: Using non-recommended spark plugs can result in serious engine damage. A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe 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 firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.
CAUTION! A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.
Incorrect fuel mixture can often cause a spark plug to appear too dark or too light in color. Before changing spark plug heat ranges, be sure the correct main jet is installed in the carburetor).
Spark Plugs Spark Plug Condition
Normal
The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.
TIP: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetor/throttle body adjustments.
Wet Fouled
The wet fouled insulator 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, use of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments.
Spark Plug Removal and Replacement
- Remove the spark plug cap.
- Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove.
- Reverse the procedure for spark plug installation.
- Torque to 18-22 ft. lbs. (24-30 Nm).
- Reinstall the spark plug cap.
natural_image
Line drawing of a mechanical tool with a handle and base (no text or symbols)MAINTENANCE Intake Filters
The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow.
NOTICE: Operating the snowmobile with the intake filters removed may cause carburetor icing. The result will be poor fuel economy or carburetor malfunction. Always reinstall the intake filters before operating the snowmobile.
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Top-down view of a motorcycle's front wheel and side-mounted brake system (no visible text or symbols)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 to have the VES disassembled, inspected and cleaned at the intervals outlined in the maintenance charts beginning on page 65.
To ensure maximum performance and minimize required maintenance, follow the oil recommendations on page 57. The use of other lubricants may cause improper function of the valve mechanism and increase the frequency of required cleaning due to excessive build-up of carbon deposits.
Fuel Pump
All fuel pump service must be performed by an authorized POLARIS dealer. Do not attempt to service the fuel pump.
Fuel Filter/Fuel Lines
See your POLARIS dealer for replacement of the fuel filter every 1000 miles (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 deterioration from weather and fuel compounds may occur. Replace worn or damaged fuel lines promptly.
NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines. If a fuel line has been damaged or kinked, replace it promptly.
Carburetor
The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. Always ensure that the correct jets are installed in the machine for the geographical area of operation.
NOTICE: Operating the snowmobile with incorrect jetting can result in serious 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 balanced is important. Properly adjusted carburetors can greatly improve engine performance, fuel economy, engine life, and reliability.
If you notice any of the following conditions, the carburetor may need adjustment:
- Hard starting
- Poor idle
• Overheated pistons and cylinder walls - Plug fouling
- Poor engine response to various throttle valve openings
MAINTENANCE
Cooling System
Coolant
POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 106 for the part numbers of POLARIS products. If the vehicle will be stored or operated at extremely low temperatures, greater protection may be required. Please see your POLARIS dealer.
Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix.
NOTICE: Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.
Coolant Level
The engine coolant level is controlled by the recovery system. The recovery system components are:
- Coolant bottle or overflow tank
- Engine filler neck
- Pressure cap
- Connecting hoses
Always maintain the coolant level at the “full cold” line on the coolant bottle when the engine is cold.
NOTICE: Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage. Always maintain the coolant level as recommended.
Cooling System
Coolant High Temperature Indicator Light
The high temperature indicator light will illuminate when engine coolant temperature becomes too hot for safe continued operation of the engine. If you must drive your machine after the high temperature indicator light has come on, drive slowly and stop frequently to allow the engine to cool down. Driving in deep snow will also help cool the engine. See your dealer for service.
Add coolant if the level is low. Engine performance will be reduced if you continue operating when the high temperature light is on.
Flushing the Cooling System
To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added. This service must be performed when the engine is cold. Ask your POLARIS dealer to check the coolant when he performs the fall tune-up on your snowmobile.
Bleeding the Cooling System
CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot.
Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part.
MAINTENANCE Cooling System Bleeding the Cooling System
NOTICE: If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced.
If coolant becomes low in the tank, bleed the system of trapped air. Perform the bleeding procedure when the engine is cold.
- Allow the system to cool completely, then loosen the bleed screw and fill the reservoir to the FULL COLD mark. Tighten the screw.
- Apply the parking brake and run the engine at idle RPM until the thermostat opens (5 to 8 minutes) and stays open.
TIP: As the thermostat draws in cold coolant from the heat exchangers, the cold coolant may close the thermostat. Make sure it opens and stays open. - Tip the snowmobile slightly onto its right side. 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 purge the air from the crossover hose or rear cooler so you can observe this air reaching the bottle. - Tilt the machine slightly onto its left side so that the coolant bottle is the highest point in the cooling system. Cycle the RPM as outlined in step 3.
TIP: There must be enough coolant flow to purge the air from the front close-off cooler so you can observe the air reaching the bottle. - Return the snowmobile to its upright position and loosen the bleed screw at the top of the water outlet manifold. When all trapped air has been purged, tighten the screw.
- Turn off the engine and release the parking brake. Allow the system to cool completely.
TIP: After cool-down, three or more ounces (88 ml) of coolant may have to be added. - Remove the pressure cap and check the coolant level. Add coolant to the fill line if necessary.
MAINTENANCE
Exhaust System
Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.
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.
Drive Chain Tension
Check drive chain tension weekly and before each long trip. To obtain correct chain tension:
-
Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.
-
Loosen the adjuster bolt jam nut (1).
-
Finger tighten the adjuster bolt (2) until it can no longer be adjusted by hand, then back off 1/4 turn.
-
Tighten the jam nut while holding the adjuster bolt.
-
Release the brake lever lock.
MAINTENANCE
Brakes
Hydraulic Brake Inspection
Inspect the brake lever reserve before each use of the snowmobile. See page 50.
Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake pads. See your dealer.
WARNING! Brake failure during operation can result in serious injury 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 inch or 1.5 mm).
Excessive Lever Travel
Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, bring the machine to an authorized POLARIS dealer for inspection and adjustment.
Brake Components
- Brake Caliper
- Chaincase
- Brake Disc
- Backing Plate
- Brake Pad Material (Replace when thickness is less than 1/16 inch/1.5 mm).
Brakes
Brake Fluid
WARNING
After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or serious injury.
Keep the master cylinder cover free of dirt and debris. The vent slits allow for diaphragm movement, and if they become plugged, movement of brake fluid below the diaphragm may be restricted, altering brake function.
View the brake fluid level through the sight glass on the top of the master cylinder. The eye will appear dark when the fluid level is full. If the sight glass is any color other than black, add brake fluid.
Maintain the brake fluid level between the MIN and MAX marks on the master cylinder reservoir. Use only POLARIS DOT 4 high temperature brake fluid. See page 106 for the part numbers of POLARIS products.
Replace brake fluid at least every two years.
NOTICE: Brake fluid will damage labels, paint and some plastics. Always wipe up spills immediately.
MAINTENANCE
Brakes
Bleeding the Hydraulic Brake System
Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile.
WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever.
During the bleeding procedure, keep the brake handle as level as possible. The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent.
- Remove the brake master cylinder reservoir cover and gasket.
- Fill the master cylinder reservoir to between the MIN and MAX marks or 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir opening. Reinstall the gasket and cover.
- Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container.
- Squeeze the brake lever a full stroke. Then unscrew the bleeder valve 3/4 of a turn to release air.
- Close the bleeder valve and release the brake lever.
- Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles.
WARNING! Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock, resulting in serious injury or death. Always add brake fluid to the fill line as recommended.
-
After bleeding is complete, refill the reservoir to the proper level. See page 81.
-
Reinstall the gasket and cover.
Lights
Headlight Adjustment
The headlight may be adjusted for vertical aim using the following procedure.
- Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wall.
- Measure the distance from the floor to the center of the headlight and make a mark on the wall.
- Start the engine and turn the headlight switch to high beam.
- Observe the headlight aim. The most intense part of the headlight beam should be aimed 2 inches (5.1 cm) below the mark placed on the wall.
TIP: Rider weight must be included on the seat.
- Turn the adjustment nut, located inside the hood, just below the headlamp opening. Turn the knob in or out as needed for proper aim.
MAINTENANCE
Lights
Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel.
Headlight Bulb Removal
-
Remove the plenum covering from the headlight assembly.
-
Pinch the ends of the spring (1) together and lift until it releases from the spring retainer.
-
Lift spring carefully around wire harness (2) and flip to outside of housing.
-
With the wire harness attached to the bulb (3), withdraw bulb from housing.
-
Grasp bulb by metal base and carefully separate bulb from harness.
Lights
Headlight Bulb Installation
- Hold the bulb by its metal base and install it into the wire harness.
- Insert the bulb into the housing.
- Connect the spring to the housing.
- Carefully flip the spring back into the housing, placing it around the wire harness.
- Reinstall the plenum covering on the headlight assembly.
- Verify headlight aim.
Taillight/Brake Light Replacement
- Remove the screws securing the taillight lens. Remove the lens.
- Push the bulb inward and turn it counterclockwise to remove it.
- Install a new bulb. Push the bulb inward and turn it clockwise to secure it.
- Reinstall the taillight lens.
MAINTENANCE
Clutch System
Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol.
WARNING! If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made.
All clutch maintenance and repairs must be performed 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 performance. See your dealer for service and adjustments. A special tool is required to check for proper alignment.
Clutch System 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 112.
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.
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 inches (3.2 cm).
Drive Belt Adjustment
-
Install the L-wrench into the open threaded hole in the outer sheave of the clutch (see page 88). Turn the wrench clockwise slightly to remove pressure from the sheaves.
-
Loosen the 7/16-inch jam nut on the belt width adjuster.
-
Using a 1/8-inch Allen wrench, turn the set screw inward (clockwise) to increase the distance between the sheaves or outward (counterclockwise) to decrease the distance.
-
Tighten the jam nut. Remove the L-wrench and store it in the tool kit.
MAINTENANCE
Clutch System Drive Belt Removal
NOTICE: Do not attempt to remove the drive belt after operating in reverse (if equipped). The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure forward engagement before attempting to remove the belt.
-
Stop the engine after operating in a forward motion. Wait for the engine to come to a complete stop.
-
Apply the brake (or lock the parking brake, if equipped).
-
Open the hood and remove the left side panel. Remove the clutch guard retaining pin and open the clutch guard.
natural_image
Close-up of a mechanical gear assembly with a hand adjusting the component (no visible text or symbols)-
Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure forward engagement.
-
Locate the L-wrench in the tool kit. Install the wrench into the open threaded hole in the outer sheave of the clutch (X).
-
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.
-
Grasp the belt at the lower edge and remove it.
Clutch System Drive Belt Installation
- Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer circumference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the break-in period. Adjust the belt ride-out after the break-in period by readjusting belt deflection.
natural_image
Line drawing of a person adjusting a car seatbelt (no text or symbols)- To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them. If required, separate the sheaves as outlined in the belt removal procedures.
- Rotate the L-wrench counterclockwise to tighten the sheaves while working the belt to the outer edge of the sheaves.
- Remove the L-wrench and store it in the tool kit.
- Close the clutch guard and reinstall the retaining pin.
- Reinstall the side panel. Close and secure the hood.
- Break in the new belt. See page 58.
Torque Stop
If the snowmobile is equipped with an engine torque stop, periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010"-.030" (.25-.75 mm) from the engine case. Adjust if necessary. Lock the jam nut.
.010"-.030" (.25-.75 mm)
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Technical line drawing of a gondola with attached components and circular markers (no text or symbols)MAINTENANCE
Fall Tune-Up
For maximum performance, arrange for a fall service tune-up with your POLARIS dealer. His experienced and trained service technician will keep your machine in peak operating condition.
Track Maintenance
WARNING
Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running.
Track Inspection
- Using a hoist, safely lift and support the rear of the snowmobile off the ground.
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.
-
Rotate the track by hand to check for damage.
-
Carefully examine the track along the entire length of each rod (X). Bend the track to check for breakage.
-
Replace the track if any rod damage is found.
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Cross-sectional view of a mechanical component with layered structure and labeled point X (no text or symbols beyond label)Track Maintenance Track Lubrication
The slide rail needs snow for lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear.
WARNING! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication.
If excessive rail slide wear occurs due to poor snow conditions, additional wheel kits are available. See your dealer for more information.
Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty.
MAINTENANCE Track Maintenance Track Tension
Track adjustment is critical for proper handling. Always maintain correct tension and alignment.
| TRACK TENSION DATA CHART | |||
| Suspension Slack Measurement Weight | Measurement Location | ||
| 600 IQ Racer 1/2-1 inch(1.25-2.54 cm) | 10 lbs.(4.54 kg) | 16 inches (40 cm) ahead of rear idler shaft | |
TIP: Tension adjustments should be made only after the track is warmed up and limber.
- Turn the engine off.
- Lift the rear of the machine and safely support it off the ground.
- 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.
- Measure at the point where the weight is hanging.
MAINTENANCE
Track Maintenance Track Tension
- Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 92.
If the track needs adjustment:
-
Loosen the rear idler shaft bolt.
-
Loosen the locknuts.
- Tighten or loosen the track adjusting screws to provide equal adjustment on both sides of the track.
NOTICE: Make sure the idler wheels do not contact the cross shaft.
- Repeat the measurement on the other side of the track.
TIP: Check more frequently when the machine is new.
-
Start the machine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brakes).
-
Check track alignment (see page 94) and adjust as necessary.
-
Tighten the locknuts.
-
Tighten the idler shaft bolts.
-
Torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).
MAINTENANCE Track Maintenance Track Alignment
Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail.
- Safely support the rear of the machine with the track off the ground.
-
Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions. Stop the engine and let the track come to a stop (do not apply brakes).
-
Inspect track alignment by looking through the track window to make sure the rails (X) are evenly spaced on each side. If the track runs to the left, loosen the idler shaft bolts, then loosen the left locknut and tighten the left adjusting bolt. If the track runs to the right, loosen the idler shaft bolts, then loosen the right locknut and tighten the right adjusting bolt.
-
After adjustments are complete, tighten the locknuts and torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).
-
Repeat steps 2 and 3 to verify proper alignment.
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Cross-sectional view of a mechanical component with internal gear-like structure (no text or symbols)Steering System Steering Inspection and Adjustment
Each week, or before a long ride, check all steering system fasteners and tighten if necessary.
MAINTENANCE
Steering System
Ski Alignment
WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or toe adjustment. See your POLARIS dealer.
If the steering feels heavy, or if the snowmobile seems to pull or dart to the side, ski alignment may need adjustment. Refer to the service manual or see your dealer for this service.
Ski Toe Settings
WARNING! Improper ski toe adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change toe adjustment. See your POLARIS dealer.
The skis on your snowmobile are set with a small amount of toe-out at the factory. You can inspect the toe setting by following the procedure below. If adjustments are required, refer to the service manual or see your dealer for this service.
- Place the handlebars in a straight-ahead position.
-
With only vehicle weight compressing the suspension, measure 10 inches (25.4 cm) forward from the center of the ski mounting bolt. See illustration. At this point, measure between the skis. This is measurement X.
-
Perform the same measurement rearward from the center of the ski mounting bolt. This is measurement Y.
-
The X measurement should be 1/8-1/4 inch (3-6 mm) greater than the Y measurement. If the skis are misaligned, see your dealer for alignment correction.
Steering System Ski Skags
WARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death.
See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.
Check skags before each use of the snowmobile to ensure positive steering characteristics. Skags must be replaced when worn to half their original 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.
- Raise and support the front of the machine so the skis are approximately 6 inches (15.2 cm) from the ground.
- Remove the attaching hardware and pry the skag downward.
- Remove the front end of the skag.
- Remove the rear end of the skag.
- Reverse the steps to install a skag.
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Technical line drawing of a skag assembly with no visible text or symbolsRail Slide Wear
Measure slide thickness at several points along the rail. Have your dealer replace the slide when it's worn down to the top of the wear limit indicator groove (X). Do not operate the snowmobile if slide thickness measures less than 7/16 inch (1.1 cm).
MAINTENANCE
Suspension Maintenance Pre-Ride Suspension Inspection
Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip.
| Item See Page | |
| Check suspension mounting bolts for tightness. See Dealer | |
| Check rear idler wheel bolts for tightness. 93 | |
| Check rear idler adjusting bolt locknuts for tightness. -- | |
| Check front torque arm limiter strap condition. -- | |
| Check rail slide condition. 97 | |
| Check track tension. 92 | |
| Check ski runner/skag condition. 92 | |
| Check ski spindle bolts for tightness. -- | |
| Check tie rod end nuts for tightness. -- | |
| Lubricate rear suspension components. 69 | |
Extended Storage
Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 106 for the part numbers of POLARIS products.
Cleaning and Preservation
Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts. Wipe down remaining surfaces with a damp cloth. Clean and touch up with paint any rusted or previously painted surfaces. Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors (grease, oil or paint).
The machine should be stored in a dry garage or shed, out of direct 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, tie rod ends and cables as outlined in the Periodic Maintenance Table beginning on page 66.
MAINTENANCE Extended Storage Clutch and Drive System
Remove the drive belt and store in a cool dry location. To prevent oxidation on the clutch sheaves, lubricate the sheave faces of the drive and driven clutches with a light coat of oil or POLARIS Cable Lubricant.
TIP: After storage, always use acetone or alcohol to remove the oil before reinstalling the drive belt.
Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer.
Engine and Carburetor Protection
Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on precision engine parts during storage. Whenever the machine is stored for a period of more than 60 days, the engine must be fogged with fogging oil. Follow the engine fogging instructions provided on the container.
Always add Carbon Clean or a fuel conditioner/stabilizer to the fuel tank. Follow the instructions on the container, running the engine for five minutes to get additives through the entire fuel system. Top off with fresh premixed fuel.
TIP: Jet restriction caused by improper storage can cause lean conditions and very poor slow speed driving quality.
Extended Storage Engine and Carburetor Protection
Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system. If you prefer to drain the fuel tank, use the following procedure
- Transfer unused fuel from the fuel tank to an approved fuel container using a siphon pump. Do not re-use fuel after storage.
- Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward.
- Remove the spark plug(s).
- Rotate the engine slowly, watching the piston until it's at bottom dead center (BDC), the lowest position in the cylinder. On twin cylinder models, the opposite piston will be up.
- Pour approximately two ounces of POLARIS injector oil into the spark plug hole.
- Wait one to two minutes and perform steps 3-5 on remaining cylinders.
- Replace the spark plugs and lower the machine to the floor.
MAINTENANCE Extended Storage Electrical Connections
Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with 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 parts.
Track and Suspension
Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely.
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Line drawing of a mechanical device with no visible text or symbolsExtended Storage Transporting the Snowmobile
Whenever the snowmobile is transported:
-
Turn the fuel valve clockwise 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.
-
Be sure the fuel cap is securely installed.
-
Tie the snowmobile to the transporting unit securely using suitable straps.
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Diagram showing two mechanical components with rotational arrows indicating motion (no text or symbols)OFF ON
SPECIFICATIONS
| 600 IQ Racer | |
| Capacities and Dimensions | |
| Body Style IQ | |
| Rider Capacity 1 Rider | |
| Coolant Capacity 5.7 qts. (5.4) | |
| Fuel Capacity 4 gal. (15.1) | |
| Oil Capacity N/A | |
| Chaincase Oil Capacity 11 oz. (325.3 ml) | |
| Gearcase Oil Capacity N/A | |
| Length 117 in. (297 cm) | |
| Designed Width 43.1 in. (109 cm) | |
| Height 47 in. (119 cm) | |
| Brake Type Hayes Phantom | |
| Drive Clutch Center Distance 10625 in. (27 cm) | |
| Drive Belt P/N 3211114 | |
| Clutch Type P-85 | |
| Reverse Transmission | N/A |
| Engine and Cooling | |
| Engine S5124-6044-OS6G | |
| Displacement | 599 cc |
| Cylinders | 2 |
| Bore x Stroke (mm) | 73.8x70 |
| Alternator Output | 220 watt |
| Carburetor/Throttle Body | 1 Rack Mikuni |
| Carburetor Model | TM40 |
| Idle RPM | 1500 +/- 200 |
| Rated Operating RPM | 8400 +/- 200 |
| Cooling | Liquid |
| Ignition Type | Digital |
| Ignition Timing | 6° BTDC @ 2000 RPM |
| Spark Plug / Gap | NGK BPR 9ES / .027 in. (0.70 mm) |
| Recommended Fuel Octane | 92 non oxygenated |
| Carburetor Settings | |
| Main Jet | 460 |
| Pilot Jet | 55 |
| Jet Needle | 9FH4-57 |
| Needle Jet | Q-0 |
| Cutaway | 1.5 |
| Throttle Gap Under CA | 2.0 |
| Fuel Screw (from fully seated) | 2.5 |
| Air Screw (from fully seated) N/A | |
| Pilot Air Jet | 0.7 |
| 600 IQ Racer | |||||||||
| Carburetor Jetting | |||||||||
| *Shaded cells indicate factory settings. | |||||||||
| ALTITUDE Meters (Feet) | AMBIENT TEMPERATURE | ||||||||
| °F: Below -25 | -30 to -10 | -15 to +5 0 | to +20 +15 | to +35 +30 to | +50 +45 to | +65 Above | +60 | ||
| °C: Below -31 | -34 to -23 | -26 to -15 | -18 to -7 -9 to | +2 -1 to +10 | +7 to +18 | Above | +16 | ||
| 0-600 (0-2000) | Main Jet | 520 | 500 | 490 | 480 | 460 | 450 | 430 | 420 |
| Pilot Jet | 55 | 55 | 55 | 55 | 55 | 55 | 55 | 55 | |
| Clip Position | #4 | #3 | #3 | #2 | #2 | #2 | #1 | #0.5 | |
| 600-1200 (2000-4000) | Main Jet | 490 | 480 | 460 | 450 | 430 | 420 | 400 | 380 |
| Pilot Jet | 55 | 55 | 55 | 55 | 55 | 55 | 55 | 55 | |
| Clip Position | #3 | #3 | #2 | #2 | #2 | #1 | #1 | #0.5 | |
| 1200-1800 (4000-6000) | Main Jet | 460 | 450 | 430 | 420 | 400 | 390 | 370 | 360 |
| Pilot Jet | 55 | 55 | 55 | 55 | 55 | 55 | 55 | 55 | |
| Clip Position | #3 | #3 | #2 | #2 | #2 | #1 | #1 | #0.5 | |
| 1800-2400 (6000-8000) | Main Jet | 430 | 420 | 400 | 390 | 370 | 360 | 340 | 330 |
| Pilot Jet | 55 | 55 | 55 | 55 | 55 | 55 | 55 | 55 | |
| Clip Position | #3 | #2 | #2 | #2 | #1 | #1 | #1 | #0.5 | |
| 2400-3000 (8000-10000) | Main Jet | 400 | 390 | 370 | 360 | 340 | 330 | 310 | 300 |
| Pilot Jet | 55 | 55 | 55 | 55 | 55 | 55 | 55 | 55 | |
| Clip Position | #3 | #2 | #2 | #1 | #1 | #1 | #1 | #0.5 | |
| 3000-3700 (10000-12000) | Main Jet | 370 | 360 | 340 | 330 | 310 | 300 | 280 | 270 |
| Pilot Jet | 55 | 55 | 55 | 55 | 55 | 55 | 55 | 55 | |
| Clip Position | #2 | #2 | #1 | #1 | #1 | #0.5 | #1 | #0.5 | |
The carburetor jetting chart above is consistent with the provisions of U.S.A. federal regulation 40 CFR 1051.115(d)(3) and is an acceptable alternative to the use of tamper-resistant features.
| 600 IQ Racer | |||||
| Clutching Chart | |||||
| ALTITUDE Meters (Feet) | Drive Clutch Shift Weight | Drive Clutch Spring | Driven Clutch Spring | Driven Helix | Chaincase Gearing/ Pitch |
| *Shaded cells indicate factory settings. | |||||
| 0-900(0-2000) | 10-58(1321588) | Almond/Red(7041988) | LH 160/280 Team(7043252) | (70/44/.46)(66/44/.46)LW NON ER(5135438) | 19:4576P |
| 900-1800(3000-6000) | 10-56(131684) | Almond/Red(7041988) | LH 160/280 Team(7043252) | (70/44/.46)(66/44/.46)LW NON ER(5135438) | 19:4576P |
| 1800-2700(6000-9000) | 10-54(1321685) | Almond/Red(7041988) | LH 160/280 Team(7043252) | (70/44/.46)(66/44/.46)LW NON ER(5135438) | 19:4576P |
| 2700-3700(9000-12000) | 10 AL(1321531) | Almond/Red(7041988) | LH 160/280 Team(7043252) | (70/44/.46)(66/44/.46)LW NON ER(5135438) | 19:4576P |
POLARIS PRODUCTS
| Part No. Description | |
| Engine Lubricants | |
| 2870791 Fogging Oil (12 oz. Aerosol) | |
| 2878243 VES RACE 2-Cycle Engine Oil (qt./.95 l) | |
| 2878191 VES RACE 2-Cycle Engine Oil (gal./3.8 l) | |
| Chaincase Lubricants | |
| 2873105 SCL - Synthetic Chaincase Lubricant (qt./.95 l) | |
| 2873106 SCL - Synthetic Chaincase Lubricant (gal./3.8 l) | |
| Grease/Specialized Lubricants | |
| 2871312 Grease Gun Kit, All Season (3 oz./89 ml) | |
| 2871322 All Season Grease (3 oz./89 ml cartridge) | |
| 2871423 All Season Grease (14 oz./414 ml cartridge) | |
| 2871329 Dielectric Grease (NyogelTM) | |
| Coolant | |
| 2880514 Antifreeze 50/50 Premix (qt./.95 l) | |
| 2880513 Antifreeze 50/50 Premix (gal./3.8 l) | |
| Additives/Miscellaneous | |
| 2871326 Carbon Clean | |
| 2870652 Fuel Stabilizer | |
| 2872189 DOT4 Brake Fluid | |
| 2872893 Engine Degreaser | |
| 2870505 Isopropyl Fuel De-Icer |
TROUBLESHOOTING
Engine Troubleshooting
Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise.
| Problem Probable Cause Solution | ||
| Erratic engine operating RPM during acceleration or load variations | Drive clutch binding | SEE YOUR DEALER. |
| Driven clutch malfunction | • SEE YOUR DEALER. | |
| Harsh drive clutch engagement | Drive belt worn or too narrow | • Replace the drive 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 | • Inspect and adjust or 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 melted to the track clips due to lack of lubrication.• Track may be iced up or frozen to the ground. | ||
| Chaincase sprocket or chain jammed or broken | • Chain is loose or broken or chain tightener is loose. SEE YOUR DEALER. | |
TROUBLESHOOTING
Engine Troubleshooting
| Problem Probable Cause Solution | ||
| Noise in drive system | Broken drive clutch components | • SEE YOUR DEALER. |
| Bearing failure/ chaincase, jackshaft, or front drive shaft | • SEE YOUR DEALER. | |
| Drive belt surface flat spots | • Inspect and replace as needed. | |
| Drive chain loose • Inspect and adjust (or replace). | ||
| Drive chain worn, sprocket teeth broken | • SEE YOUR DEALER. | |
| Poor low RPM performance | 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 92 octane fuel. | ||
| Engine doesn't turn Seized engine • SEE YOUR DEALER. Seizure is a result of poor lubrication, inadequate fuel supply, broken parts or improper cooling. | ||
| Engine requires more than normal pulls to start | Poor fuel • Replace with fresh premixed winter fuel. | |
| Not enough fuel getting to engine | • SEE YOUR DEALER. | |
TROUBLESHOOTING
Engine Troubleshooting
| Problem Probable Cause Solution | ||
| Engine turns but fails to start | Faulty ignition • Install new spark plug(s). If engine still fails to start, check for spark. If there's no spark, SEE YOUR DEALER. | |
| No fuel to engine • Make sure the fuel valve is on.Make sure the fuel tank contains fuel.Ice may be in the fuel line, filter or pump. Add isopropyl alcohol to the fuel system. | ||
| Flooded engine (normal situation caused by too much choking) | Hold throttle open, crank engine several times (may need to dry or change plug(s)) | |
| Poor engine compression | Mixture 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 power Fouled or defective spark plug(s) | Replace the plug(s). | |
| SEE YOUR DEALER. | ||
| SEE YOUR DEALER. | ||
| There's no adjustment to change power output. 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-ethanol fuel at all times for assurance against fuel line icing). | ||
| Engine backfires but fails to start | Spark plug wires may be on wrong cylinder | Reinstall spark plug wires to the corresponding cylinder. |
TROUBLESHOOTING
Suspension Troubleshooting
| Problem Solution | |
| Rear suspension bottoms too easily | Adjust torsion spring preload (see page 40).Increase rear shock compression damping by turning screw clockwise.Increase torsion spring wire diameter (see your dealer). |
| Rides too stiff in rear | Check for binding suspension shafts and grease all pivot points.Adjust torsion spring preload (see page 40).Decrease rear shock compression valving by turning screw counter-clockwise (if Indy Select shock)Change to lighter valving (if FOX shock)Check track tension (see page 92). |
| Too much weight transfer when climbing | Adjust torsion spring preload (see page 40).Adjust limiter straps. |
| Too little weight transfer when climbing | Adjust torsion spring preload (see page 40).Adjust limiter straps. |
| Machine darts from side to side | See your dealer for ski alignment inspection.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.Adjust torsion spring preload (see page 40).Check rail slide/replace if worn (see page 97).Reduce ski pressure: Reduce IFS spring preload or reduce rear torsion spring preload. |
TROUBLESHOOTING
Suspension Troubleshooting
| Problem Solution | |
| Front end pushes • Check for worn skags. | Adjust torsion spring preload (see page 40).Check for binding front suspension shafts and steering components, grease all pivot points (elevate front of machine).Increase IFS preload (if equipped) (see page 35).Install single skag (see your dealer).Rotate RRSS to high position (see page 45). |
| Steering is heavy • Make sure spindles and all steering components turn freely. | See your dealer for ski alignment inspection.Check skags and skis for damage.Reduce ski pressure: Increase front track spring preload, reduce IFS spring preload by adjusting cam, reduce rear torsion spring preload (see page 40). |
| Setting up for deep snow operation | • Change worn rail slide. |
TROUBLESHOOTING
Drive Belt Troubleshooting
| Belt Wear/Burn Diagnosis | |
| Causes Solutions | |
| Driving at low RPM • Drive | at higher RPMs. Gear the machine down. Check belt deflection. |
| Insufficient warm-up • 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. |
| Towing at low RPM • Do not tow in deep snow. Use fast, aggressive throttle to engage clutch. | |
| Riding with high RPM and slow speed (8000 RPM/10 MPH) | • Lower the gear ratio. Remove windage plates from the clutch. Reduce RPM. Avoid riding in 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 and warm it up. Break machine loose from the snow. |
| Poor engine performance • | Check for carburetor and choke synchronization, fouled plugs, debris in the carburetor(s) and water, ice or dirt in the fuel tank or fuel line. |
| Loading machines onto trailers | • Skis may gouge into trailers and prevent the drivetrain from spinning properly. Use enough speed to drive the machine completely onto the trailer. Push and pull it to finish loading if necessary. |
| Clutch malfunction • Inspect | clutch components. See your dealer. |
| Slow, easy clutch engagement | • Use fast, aggressive throttle to engage clutch. |
Service and Warranty Information Obtaining Service and Warranty Assistance
Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information 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:
- Serial number
- Model number
- Dealer name
- Date of purchase
- Details of trouble experienced
- Length of time and conditions of operation
- Previous correspondence
Use the page provided near the front of your owner's manual to record the identification numbers of your snowmobile and its engine.
POLARIS Customer Service
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
WARRANTY
Limited Warranty
POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a 12 MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
THIS WARRANTY MAY BE VOIDED BY ANY UNAPPROVED MODIFICATIONS TO THIS VEHICLE THAT AFFECT POWERTRAIN, EXHAUST, CHASSIS OR SUSPENSION.
Promotional warranties are sometimes offered by POLARIS, including but not limited to:
- Two-year extended engine coverage
- Two-year powertrain coverage
- Extended service contract
See your dealer for details and separate terms and conditions for any promotional warranties.
Registration
At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage. If you have not signed the original registration and received the customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.
Warranty Coverage and Exclusions Limitations of Warranties and Remedies
This POLARIS Limited Warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed.
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/contamination; improper maintenance; modified components; use of aftermarket components; unauthorized repairs; repairs made after the warranty period expires or by an unauthorized repair center; use of the product in competition or for commercial purposes. Warranty will not apply to any product which has been damaged by abuse, accident, fire or any other casualty not determined a defect of materials or workmanship.
This warranty excludes damages or failures caused by abuse, accident, fire or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:
Skis Ski wear rods
Tracks Slide rails
Suspension components Finished and unfinished surfaces
Brake components Carburetor/Throttle body components
Seat components Engine components
Clutches and components Drive belts
Steering components Hydraulic components
Batteries Circuit breakers/Fuses
Light bulbs/Sealed beam lamps Electronic components
Idler wheels Spark Plugs
Sealants Lubricants
Coolant Filters
Fuel
WARRANTY
Warranty Coverage and Exclusions Limitations of Warranties and Remedies
Lubricants and Fluids
- Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil.
- Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.
This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE 12 MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.
How to Obtain Warranty Service
If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.
In the country where your product was purchased:
Warranty or service bulletin repairs must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your product was purchased, warranty and service bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product.
Outside the country where your product was purchased:
If you are traveling temporarily outside the country where your product was purchased, you should take your product 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 perform the warranty repair.
If you move:
If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Product importation rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS in order to register your product in your new country. You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle.
If you purchase from a private party:
If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
WARRANTY Exported Products
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions. This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer's authorized location. This policy does not apply to safety bulletins.
Notice
If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty.
Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries. If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect.
For questions call POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
U.S.A. EPA Emissions Limited Warranty
This Emissions Limited Warranty is in addition to the POLARIS standard Limited Warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations.
The warranty period for this emissions-certified vehicle starts on the date the vehicle is first purchased and continues for a period of 200 hours of engine operation; 4,000 kilometers (2,485 miles) of vehicle travel; or 30 calendar months from the date of purchase, whichever comes first.
This Emissions Limited Warranty covers components if their failure increases the vehicle's regulated emissions, and it covers components of systems if their only purpose is to control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This Emissions Limited Warranty does not cover components if their failure does not increase the vehicle's regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to the following systems:
• Air-induction system • Ignition system
- Fuel system • Exhaust gas recirculation systems
The following parts are also considered emission-related components for exhaust emissions:
- Aftertreatment devices • Sensors
- Crankcase ventilation valves • Electronic control units
The following parts are considered emission-related components for evaporative emissions:
- Fuel Tank • Vacuum Control Diaphragms*
- Fuel Cap • Control Cables*
- Fuel Line • Control Linkages*
- Fuel Line Fittings • Purge Valves
- Clamps* • Vapor Hoses
- Pressure Relief Valves* • Liquid/Vapor Separator
• Control Valves* • Carbon Canister - Control Solenoids* • Canister Mounting Brackets
- Electronic Controls* • Carburetor Purge Port Connector
*As related to the evaporative emission control system.
WARRANTY
U.S.A. EPA Emissions Limited Warranty
The exclusive remedy for breach of this Limited Warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law.
This Limited Warranty excludes failures not caused by a defect in material or workmanship. This Limited Warranty does not cover damage 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 performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle. POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that you use only POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering with emission controls is prohibited by federal law.
If you have any questions regarding your warranty rights and responsibilities, please contact POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
MAINTENANCE LOG
Present this section of your manual to your dealer each time your snowmobile 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) | |||
MAINTENANCE LOG
| DATE | MILES (KM) | TECHNICIAN SERVICE PERFORMED / COMMENTS |
MAINTENANCE LOG
| DATE MILES (KM) | TECHNICIAN SERVICE PERFORMED / COMMENTS | |
INDEX
A
Accessories 46
Air Pollution 6
Avalanche Awareness 21
Avalanche Danger Scale ..... 22
Avalanches....15-22
B
Brake Components.... 80
Brake Fluid 50,81
Brake Inspection 80
Brake Lever Travel 50,80
Brake Light Replacement 85
Brake System Bleeding 82
Brakes 50,80-82
Break-In Period 56-58
C
Carbide Skags 47
Carburetion 62
Carburetor 75
Carburetor Adjustments.... 75
Carburetor Jetting 105
Carburetor Protection. . . . . . . 100-101
Chaincase Oil. 71
Choke.... 71
Choke Cable Lubrication.... 70
Choke Lubrication.... 70
Cleaning and Preservation. 99
Clutch Alignment Offset ..... 86
Clutch and Drive System..... 100
Clutch Cover Warning. 28
Clutch Safety 25
Clutch System 86-89
Clutching 105
Cold Weather Drive-Away ..... 25
Compression Damping
Front Suspension ..... 36-37
Rear Suspension ..... 41-42
Controls and Linkage. 99
Coolant. 76
Coolant Level. 76
Cooling System 76-78
Cooling System, Bleeding.....77-78
Cooling System, Flushing ..... 77
Customer Service.... 113
D
Disabled Operators ..... 12
DRAGON Ignition System ..... 32-33
DRAGON Mode Facts ..... 32
Drive Belt 25
Drive Belt Adjustment 87
Drive Belt Break-In. 58
Drive Belt Condition....87
Drive Belt Deflection 87
Drive Belt Installation. 89
Drive Belt Removal. 88
Drive Chain Tension 79
Driver Awareness 14
Driving Downhill 24
Driving in Hilly Terrain 24
Driving on Slippery Surfaces ..... 23
Driving Responsibly 26
E
Electrical Connections ..... 102
Emissions Limited Warranty.. 119-120
Engine Break-In 56-58
Engine Protection ..... 100-101
Engine Safety 10
Engine Starting 59
Engine Stop Switch. 60
Environment 6
Exhaust System 79
Exhaust System (VES) 74
F
Front Rear Scissor Stop. 44
Front Springs....38
Front Suspension Adjustments .. 34-38
Fuel Filter 75
Fuel Lines 75
Fuel Premix....57
Fuel Pump 74
Fuel Recommendations. 57
Fuel Safety 55
Fuel System Deicers 58
H
Handlebar Adjustments. 46
Handlebar Angle. 46
Handlebar Position 46
Headlight Adjustment.... 83
Headlight Bulb Installation..... 85
Headlight Bulb Removal 84
High Compression Damping
Front Track Suspension ..... 41
IFS. 36
Rear Track Suspension ..... 41
High Temperature Light 77
Hood Latches 53
|
Ice and Snow Build-up 23
IFS....34
IFS Adjustment Options ..... 34
IFS Components 34
Inadequate Snow Conditions ..... 23
Intake Filters. 74
Intake Silencer 25
J
Jetting Guidelines 62
L
Lights 83-85
Low Compression Damping
Front Track Suspension ..... 42
IFS. 37
Rear Track Suspension ..... 42
Lubrication 69-71
M
Maintenance Interval Table .... 66-68
Maintenance Program. 65
Maneuverability 25
Mountainous Terrain Riding . . . 15-22
N
Noise. 6
O
Oil Recommendations ..... 57
Operating in Deep Snow 23
Operation Warning. 29
Operator Safety.... 8-27
P
Parking Brake Lever Lock ..... 51
PassengerWarnings 28
Preload, IFS Shock Spring ..... 35
Pre-Ride Checklist 48
Pre-Ride Suspension Inspection.... 98
Pressure Cap Warning 28
R
Rail Slide Wear 97
Rear Rear Scissor Stop. 44
Rear Suspension Adjustments . . 39-45
Rebound Damping
IFS 38
Rear Track Suspension. . . . . . 43
Recoil Rope 53
Recommended Maintenance ..... 9
Registration, Warranty ..... 114
Rider Capacity 13
Riding Apparel 11
Riding Position. 10
INDEX
S
Safety Labels 28-30
Safety Symbols 8
Scissor Stop, Front Rear ..... 44
Scissor Stop, Rear Rear ..... 44
Shock Valving 36
Signal Words 8
Ski Alignment 96
Ski Skags 97
Ski Toe Settings.... 96
Slide Rail and Track Cooling ..... 61
Snow Conditions 23
Spark Plug Condition....72-73
Spark Plug Removal 73
Spark Plugs 72-73
Speed 13
Spring Preload, IFS Shock. 35
Starting the Engine 59
Steering Inspection/Adjustment.... 95
Steering Post Lubrication ..... 69
Steering System ..... 52, 95-97
Stopping, Emergency.... 60
Storage, Daily 63
Storage, Extended ..... 99-103
Studs 47
Survival Preparation 12
Suspension Coupling.... 43
Suspension Inspection, Pre-Ride... 98
Suspension Lubrication, Front. . . . 69
Suspension Lubrication, Rear ..... 69
Suspension Maintenance ..... 98
Suspension Performance Tips ..... 39
Switches 54
Engine Stop Switch 60
Hand/Thumbwarmer Switch . . 31
Headlight Dimmer Switch.... 31
Ignition System Switch ..... 31
T
Taillight/Brake Light Replacement. . 85
Tether Switch 54
Throttle Cable 70
Throttle Lever 49
Torque Stop. 89
Torsion Spring Tension. 40
Towing 63
Track 52
Track Alignment 94
Track Care for Storage ..... 102
Track Inspection 90
Track Lubrication....91
Track Maintenance ..... 90-94
Track Safety 10
Track Tension 39, 92-93
Track Warm-Up 61
Track Warning 28
Traction Products 47
Transporting the Snowmobile....103
Troubleshooting, Drive Belt ..... 112
Troubleshooting, Engine..... 107-109
Troubleshooting, Suspension. 110-111
Tune-Up 90
V
Variable Exhaust System ..... 74
Vehicle Identification Numbers ..... 5
W
Weight Transfer 45
Windchill....27
POLARIS®
For your nearest Polaris dealer, call 1-800-POLARIS (765-2747)
or visit www.polaris.com
Polaris Industries Inc.
2100 Highway 55
Medina, MN 55340
Part No. 9926025 Rev 01
Printed in USA
- WARNING
- WELCOME
- POLARIS®
- TABLE OF CONTENTS
- Introduction 5
- Safety 8
- Features 31
- The Perfect Fit 34
- Pre-Ride Inspections 48
- Operation 55
- Maintenance 64
- Specifications.... 104
- POLARIS Products. 106
- Troubleshooting.... 107
- Warranty 113
- Maintenance Log 121
- Index 124
- INTRODUCTION
- Important Notes for Owners and Drivers
- Preservation of the Environment
- Noise Level
- Air Pollution
- Vehicle Identification Numbers
- SAFETY
- Operator Safety
- DANGER
- CAUTION
- NOTICE
- Operator Safety Stay Clear of Track
- Stay Clear of Engine
- Riding Position
- Operator Safety Riding Apparel
- Helmet
- Eye Protection
- Clothing
- Disabled Operators
- Survival Preparation
- Operator Safety Rider Capacity
- Excessive Speed
- Operator Safety Driver Awareness
- Operator Safety Mountainous Terrain Riding
- Mountainous Terrain Riding
- Get the Safety Gear
- Operator Safety Mountainous Terrain Riding Get to Know Your Safety Gear
- Get Avalanche Safety Training
- Get the Forecast
- Get the Picture
- Operator Safety Mountainous Terrain Riding Get Out of Harm's Way
- Get to Know Your Mountain Snowmobile
- Do not ride in mountainous terrain until you are comfortable riding and controlling your snowmobile in deep snow.
- Operator Safety Mountainous Terrain Riding Avalanche Awareness
- Operator Safety Ice and Snow Build-up
- Driving on Slippery Surfaces
- Inadequate Snow Conditions
- Operating in Deep Snow
- Operator Safety Driving Downhill
- Driving in Hilly Terrain
- Operator Safety Drive Belt
- Intake Silencer
- Clutches
- Cold Weather Drive-Away
- Maneuverability
- Operator Safety Driving Responsibly
- Operator Safety Windchill/Temperature Charts
- Safety Labels and Locations
- Clutch Cover Warning
- Pressure Cap Warning
- No Passenger Warning
- Track Warning
- Safety Labels and Locations Operation Warning
- SAFETY Safety Labels and Locations
- Competition ONLY Warning
- FEATURES
- POLARIS DRAGON Ignition System
- DRAGON Mode Facts
- THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS)
- IFS Components
- IFS Adjustment Options
- THE PERFECT FIT
- Front Suspension Adjustments Shock Spring Preload
- Front Suspension Adjustments Shock Valving (Walker/Evans Shocks)
- Compression Damping
- High Compression Damping Force Adjustment
- Front Suspension Adjustments
- Low Compression Damping Force Adjustment
- THE PERFECT FIT Front Suspension Adjustments
- Rebound Damping Force Adjustment
- Front Springs
- Rear Suspension Adjustments
- Suspension Performance Tips
- Track Tension
- Torsion Spring Tension
- Cam Adjustments
- Rear Suspension Adjustments Compression Damping High Compression Damping Force Adjustment
- THE PERFECT FIT Rear Suspension Adjustments Compression Damping Low Compression Damping Force Adjustment
- Rebound Damping Force Adjustment (Rear track suspension only)
- Suspension Coupling
- Rear Suspension Adjustments Front Rear Scissor Stop (FRSS)
- Rear Rear Scissor Stop (RRSS)
- Rear Rear Scissor Stop - Attributes
- Rear Suspension Adjustments Weight Transfer During Acceleration
- Rearward Upper Position
- THE PERFECT FIT Handlebar Adjustments Handlebar Position
- Handlebar Angle
- Accessories
- Traction Products Studs
- Traction Products Carbide Skags
- PRE-RIDE INSPECTIONS
- Pre-Ride Checklist
- Before Starting the Engine
- Read and Understand Your Owner's Manual
- Throttle Lever
- PRE-RIDE INSPECTIONS Before Starting the Engine Brakes
- Brake Lever Travel
- Lever Feel
- Brake Fluid
- Before Starting the Engine Parking Brake Lever Lock
- Lock Engagement
- Lock Release
- Steering System
- Track
- Before Starting the Engine Hood Latches
- Seat Latches
- Recoil Rope
- PRE-RIDE INSPECTIONS Start the Engine and Check
- Engine Stop Switch
- Tether Switch
- Lighting
- Mirrors (if equipped)
- Operating Area
- Fuel Safety
- OPERATION Break-In Period Engine Break-In
- Break-In Period
- Engine Break-In
- Oil Recommendations
- Fuel Recommendations
- Fuel System Deicers
- Drive Belt Break-In
- Starting the Engine
- Starting a Cold Engine
- Starting a Warm Engine
- OPERATION Emergency Stopping
- Track Warm-Up
- Slide Rail and Track Cooling
- OPERATION
- Carburetion
- Jetting Guidelines
- Daily Storage
- Towing
- MAINTENANCE Emission Control Information
- Emission Control Label
- Emission Control Maintenance Requirements
- Owner's Responsibilities
- Non-ionizing Radiation
- MAINTENANCE
- POLARIS Recommended Maintenance Program
- Periodic Maintenance Interval Table
- Lubrication
- Front Suspension
- Rear Suspension
- Throttle Cable
- Choke and Choke Cable
- Lubrication Chaincase Oil
- Oil Check
- Spark Plugs
- Spark Plug Condition
- Spark Plugs Spark Plug Condition
- Normal
- Wet Fouled
- Spark Plug Removal and Replacement
- MAINTENANCE Intake Filters
- Variable Exhaust System (VES)
- Fuel Pump
- Fuel Filter/Fuel Lines
- Carburetor
- Carburetor Adjustments
- Cooling System
- Coolant
- Coolant Level
- Coolant High Temperature Indicator Light
- Flushing the Cooling System
- Bleeding the Cooling System
- MAINTENANCE Cooling System Bleeding the Cooling System
- Exhaust System
- Drive Chain Tension
- Brakes
- Hydraulic Brake Inspection
- Excessive Lever Travel
- Brake Components
- Bleeding the Hydraulic Brake System
- Lights
- Headlight Adjustment
- Headlight Bulb Removal
- Headlight Bulb Installation
- Taillight/Brake Light Replacement
- Clutch System
- Clutch Alignment Offset
- Clutch System Drive Belt Condition
- Drive Belt Deflection
- Drive Belt Adjustment
- Clutch System Drive Belt Removal
- Clutch System Drive Belt Installation
- Torque Stop
- Fall Tune-Up
- Track Maintenance
- Track Inspection
- Track Maintenance Track Lubrication
- MAINTENANCE Track Maintenance Track Tension
- Track Maintenance Track Tension
- If the track needs adjustment:
- MAINTENANCE Track Maintenance Track Alignment
- Steering System Steering Inspection and Adjustment
- Ski Alignment
- Ski Toe Settings
- Steering System Ski Skags
- Skag Replacement
- Rail Slide Wear
- Suspension Maintenance Pre-Ride Suspension Inspection
- Extended Storage
- Cleaning and Preservation
- Controls and Linkage
- MAINTENANCE Extended Storage Clutch and Drive System
- Engine and Carburetor Protection
- Extended Storage Engine and Carburetor Protection
- MAINTENANCE Extended Storage Electrical Connections
- Track and Suspension
- Extended Storage Transporting the Snowmobile
- TROUBLESHOOTING
- Engine Troubleshooting
- Suspension Troubleshooting
- Drive Belt Troubleshooting
- Service and Warranty Information Obtaining Service and Warranty Assistance
- POLARIS Customer Service
- WARRANTY
- Limited Warranty
- Registration
- Warranty Coverage and Exclusions Limitations of Warranties and Remedies
- Lubricants and Fluids
- How to Obtain Warranty Service
- WARRANTY Exported Products
- U.S.A. EPA Emissions Limited Warranty
- MAINTENANCE LOG
- INDEX
- A
- B
- C
- D
- E
- F
- H
- High Compression Damping
- |
- J
- L
- Low Compression Damping
- M
- N
- O
- P
- R
- Rebound Damping
- S
- T
- V
- W
Brand : POLARIS
Model : 600 IQ Racer (2016)
Category : Snowmobile