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Polaris 600 EDGE Touring Owner's Manual

Polaris 2006 snowmobile owner's manual
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  • Page 3 Read, 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. PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust, which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm, onto the snow on which they operate.
  • Page 4 Polaris enthusiasts. Be sure to visit us online at www.polarisindustries.com for the latest news, new product introduc- tions, upcoming events, career opportunities and more. Here at Polaris we proudly produce an exciting line of utility and recre- ational products. • Snowmobiles •...
  • Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 6: Table Of Contents

    Polaris Products..... . . 134 Troubleshooting ..... . . 135 Warranty .

  • Page 7: Introduction

    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.

  • Page 8: Preservation Of The Environment

    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 wel- come to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others.

  • Page 9: Safety

    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 sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.
  • Page 10 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.

  • Page 11: Safety

    SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be par- tially 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.

  • Page 12: Riding Position

    Operator Safety 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.

  • Page 13: Survival Preparation

    SAFETY Operator Safety 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 condi- tions you may encounter.

  • Page 14: Disabled Operators

    A decal on the console of these models indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders. A decal on the hood of these models indicates that the vehicle is designed for one operator and one passenger only.

  • Page 15: Excessive Speed

    SAFETY Excessive Speed WARNING High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per sec- ond your machine travels.

  • Page 16: Driver Awareness

    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.
  • Page 17 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • Take an avalanche class • Travel with experienced people • Travel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon.

  • Page 18: Ice And Snow Build-Up

    Operator Safety Ice and Snow Build-up WARNING Ice and snow build-up may interfere with the steering of your machine, result- ing in serious injury or death. Keep the underhood area free of snow and ice. 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.

  • Page 19: Driving Downhill

    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.

  • Page 20: Drive Belt

    Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly terrain.

  • Page 21: Clutch Guard

    SAFETY Operator Safety Clutch Guard Do not operate the engine with the clutch guard removed. The clutch guard is designed to protect the operator from metal parts if the clutch should fail. Although the chance of failure is extremely remote, don't defeat the purpose of the safety guard by removing it. Clutches Do not attempt to service the clutches.

  • Page 22: Inadequate Snow Conditions

    They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20_ F), Polaris recommends closing the upper hood closure. WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury.

  • Page 23: Driving Responsibly

    SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile condi- tions 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 driv- ers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
  • Page 24 Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WINDCHILL CHART (_F) Wind Speed Calm Frostbite in >> 30 min. WINDCHILL CHART (_C) Wind Speed Calm -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67...

  • Page 25: Clutch Cover Warning

    If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.

  • Page 26: Track Warning

    Entanglement with the track or a fall from seat back can result in severe injury or death. Passenger Warning Polaris touring models and the WideTrak are designed for the operator and one passenger. For more information on operating with a passenger, see page 11.

  • Page 27: Safety Decals And Locations

    SAFETY Safety Decals and Locations Standard Reverse Warning The Polaris WideTrak snow- mobile is equipped with stan- dard reverse. The reverse warning decal is located above the instrument housing: WARNING Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death.
  • Page 28 Safety Decals and Locations Electronic Reverse Warning Polaris snowmobiles equipped with electronic reverse have a reverse warning decal on the lower dash: WARNING Reverse operation, even at low speeds, can cause loss of con- trol resulting in serious injury or death. To avoid loss of con- trol, always: •...

  • Page 29: Operation Warning

    • To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, con- tact a Polaris dealer for a replacement. • This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control.

  • Page 30: Features

    Some Polaris snowmobiles are equipped with special features. Operat- ing controls and special feature controls are illustrated on this page. Not all models come with all special features. See your Owner's Manual Supplement. 1. Fuel Filler Cap 2. Ignition Switch 3.
  • Page 31 FEATURES...

  • Page 32: Features

    1. Hood 2. Headlight 3. Passenger Lumbar Adjuster (Touring) 4. Windshield 5. Handlebar 6. Operator Seat 7. Passenger Seat 8. Trunk Cover 9. Taillights 10. Rear Bumper FEATURES 11. Snow Flap 12. Passenger Grab Handle 13. Track 14. Suspension 15. Trailing Arm 16.

  • Page 33: The Perfect Fit

    THE 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.

  • Page 34: Shock Components

    Shock Components 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. 1. Retainer 2. Shock Rod 3. Jounce Bumper 4.
  • Page 35 THE PERFECT FIT Front Suspension Adjustments Shock Damping (Indy Select Shock) Adjustments to the compression stiff- ness of Indy Select shocks can be made by turning the adjustment screw located near the base of the shock (✪). This adjustment is the easiest to per- form and it should be considered first.

  • Page 36: Spring Preload

    Front Suspension Adjustments 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.

  • Page 37: Shock Valving

    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. Front Springs For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn't sufficient and fur- ther adjustment is desired to control suspension stiffness.

  • Page 38: Rear Suspension Adjustments

    Refer to the suspension setup label on your snowmobile, or see your Polaris dealer for initial suspension setup information. Additional adjustments can be made after initial setup. Make adjustments to one area at a time so you can evaluate the change. For further assistance, see...

  • Page 39: Suspension Performance Tips

    Bogie wheel kits are available from your dealer. • Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.
  • Page 40 EDGE 136 Rear Suspension Adjustments (Indy 340 Touring) Initial Spring Preload Setting (Sag Method) To set up the EDGE rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement Take the first measurement with no rider and with the rear suspension at full extension.

  • Page 41: Rear Spring Tension

    THE PERFECT FIT EDGE 136 Rear Suspension Adjustments (Indy 340 Touring) Rear 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. The following information is provided only as a guideline to be used for initial suspension set-up.
  • Page 42 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments (Indy 340 Touring) Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving. Locate the adjust- ment screw near the base of the shock. In half-turn increments, turn the screw clockwise to increase compression valving and stiffen the ride, or counterclockwise to reduce compression and soften the ride.

  • Page 43: Suspension Coupling

    Contact your dealer for more information. 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 sus- pension coupling, these torque arms could move independently of each other.
  • Page 44 THE PERFECT FIT EDGE 136 Rear Suspension Adjustments (Indy 340 Touring) Suspension Coupling Rear To Front Coupling and the 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 indepen- dent movement between the rear torque and the front torque arm.

  • Page 45: Weight Transfer During Acceleration

    THE PERFECT FIT EDGE 136 Rear Suspension Adjustments (Indy 340 Touring) Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding condi- tions.
  • Page 46 EDGE Touring Suspension (ETS) Adjustments Torsion Springs Two torsion springs are used on the rear arm of the ETS. Preload adjustments can be made by turning the rectangular adjusters with a spark plug wrench. The firm torsion spring should be used if fre- quent bottoming is encountered during two up riding on rough trails.
  • Page 47 THE PERFECT FIT EDGE Touring Suspension (ETS) Adjustments The following information has been compiled to assist you in tuning your ETS to its maximum potential. The Ride Control Adjuster (RCA) 1. Refer to the initial setup reference chart (located under the hood of your snowmobile and on page 43) to determine the desired RCA position.
  • Page 48 EDGE Touring Suspension (ETS) Adjustments Front Arm Mounting Holes There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole increases ski pressure while the upper hole decreases ski pressure. Increase pressure THE PERFECT FIT Decrease...
  • Page 49 THE PERFECT FIT WideTrak Rear Suspension Adjustments Rear Spring Settings Rear spring adjustment is primarily a control for riding comfort. To check for the recommended settings: 1. Lift the rear of the machine to relieve the rear springs. 2. Slowly lower the machine and measure the distance between the ground and the running board.

  • Page 50: Handlebar Adjustments

    Handlebar Adjustments Handlebar Angle Follow these steps to adjust handlebar angle at the handle- bar block. 1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster block bolts (2). 2. Using a 7/16I (11 mm) wrench, loosen the four nuts (3) on the bottom of the adjuster block (turn handlebar to left or right...
  • Page 51 THE PERFECT FIT Passenger Grab Handle Adjustment On some Touring models the position of the passenger grab handles can be adjusted for rider preference. 1. Unscrew and remove the knob assemblies that secure the grab handles. 2. Reposition the grab handles to one of the three available positions on the grab handle tube between the operator...
  • Page 52 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 •...

  • Page 53: Traction Products

    Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. NOTE: Polaris does not recommend the use of traction products on WideTrak snowmobiles. Use only Polaris traction products on your snowmobile. Track warran- ties are void if track damage or failure results from improper or exces- sive stud installation or the use of non-Polaris traction products.
  • Page 54 Traction Products nCarbide 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.

  • Page 55: Wear Strips

    THE PERFECT FIT Traction Products Wear Strips To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. See your dealer for more information. Some models are manufactured with tunnel wear strips or wear strip coolers installed.

  • Page 56: 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 refer- enced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Drive Belt Condition Steering System Recoil Rope...

  • Page 57: Before Starting The Engine

    PRE-RIDE INSPECTIONS Before Starting the Engine WARNING Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all 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.
  • Page 58 Before Starting the Engine n Hydraulic 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 1/2I (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.

  • Page 59: Park Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine n Park Brake Lever Lock If your model is equipped with the park brake lever lock, use the 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. 1.

  • Page 60: Steering System

    Before Starting the Engine n Steering System WARNING Ice and snow build-up may interfere with the steering of your machine, result- ing in serious injury or death. Keep the underhood area free of snow and ice. 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.

  • Page 61: Hood Latches

    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. n Transmission Make sure the transmission is not in reverse before starting the engine...

  • Page 62: Start The Engine And Check

    Start the Engine and Check 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. Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF. Tether Switch If your machine has a tether switch, remove the tether from the switch to make sure the engine stops immediately.

  • Page 63: Operation

    OPERATION Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Before Starting the Engine beginning on page 54. 1.
  • Page 64 Premix the first tank of fuel with one pint of Polaris injection oil for each five gal- lons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

  • Page 65: Oil Injection System

    Engine lubrication comes from oil added to the fuel and oil injection systems. On Polaris snowmobiles equipped with a variable exhaust sys- tem (VES), Polaris highly recommends the use of only VES II 2 Cycle Oil. See the table below for additional oil recommendations. See page 134 for the part numbers of Polaris products.

  • Page 66: Track Warm-Up

    Track Warm-Up WARNING A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throt- tle during warm-up or when the track is free-hanging.

  • Page 67: Fuel Valve

    OPERATION Fuel Valve 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. Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. •...

  • Page 68: Premium Fuel Switch

    ON/REG. The Premium Fuel light will go out. This setting will adjust the timing of your engine to run on fuels with 87 octane or higher. Polaris does not recommend using fuel with lower than 87 octane. Running your machine on ON/REG will help protect your engine from damage caused by low octane fuels.

  • Page 69: Fuel System Deicers

    RES. Fuel System Deicers If you use non-oxygenated fuel, Polaris recommends the regular use of isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures.

  • Page 70: Low Oil Indicator Light

    When the oil reaches the low level mark, add one U.S. quart of recommended oil. See page 62 for oil recommenda- tions. NOTE: The Polaris oil cap on the oil bottle is vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.
  • Page 71 Either condition may be caused by improper carburetor adjustment. WARNING Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage. Always have your Polaris dealer perform any carburetor adjustments.

  • Page 72: Jetting Guidelines

    Carburetion 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.

  • Page 73: Engine Stop Switch

    OPERATION Engine Stop Switch Push down on the engine stop switch (✪) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.

  • Page 74: Throttle Lever

    When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the machine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealer for service as soon as possible. OPERATION...

  • Page 75: Passenger Seat

    OPERATION Passenger Seat The passenger seat features an adjustable lumbar support. To adjust for rider com- fort, rotate the lumbar adjustment knob. The passenger seat and trunk cover are removable. Removing the cover and seat will provide open storage for transporting larger items.

  • Page 76: Emergency Starting

    Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Snowmobiles equipped with electric start have a recoil for emergency starting. On non-electric-start models, if the recoil starter system fails, an emergency start strap is provided in the kit. 1.

  • Page 77: Reverse Operation

    OPERATION Reverse Operation WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed.
  • Page 78 Reverse Operation Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. If your machine is running at an altitude of over 6000 feet, adjust the igni- tion setting as described on page 76. Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse.

  • Page 79: Altitude Setting

    OPERATION Reverse Operation Electronic Reverse (PERCt) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button for one second and release. The engine will slow and begin to rotate forward. The light on the instrument panel will shut off.

  • Page 80: Daily Storage

    Daily Storage At the end of each ride, park the snow- mobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4I (10 cm) off the ground. Remove the key and cover the machine. 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.

  • Page 81: Maintenance

    MAINTENANCE Emission Control Information (340cc and 600cc Engines Only) Emission Control Label Your snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa- tion hangtag. These items are required by U.S. Environmental Protection Agency regulations.
  • Page 82 Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.

  • Page 83: Maintenance

    Personal safety is critical when attempting to service or make adjust- ments 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 comfort- able performing these tasks yourself, contact an authorized Polaris dealer for service. CAUTION Hot components can cause damage to plastic.
  • Page 84 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 Clutch Alignment Offset...
  • Page 85 MAINTENANCE Periodic Maintenance Interval Table Item Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake Fluid Pilot Air Screws Carburetor (synchronize) Idle RPM Throttle Lever Oil Pump Lever (synchronize) Throttle Cable Choke Cable Choke Vent Lines Throttle Position Sensor...
  • Page 86 Periodic Maintenance Interval Table Item Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fas- teners Suspension Shock Oil Cooling Fins and Shroud Drive Shaft Bearing Jackshaft Bearings Skags (Wear Bars) Ski Saddle/Spindle Bolts Ski Pivots Ski Spindle Steering Arm(s) Upper / Lower Steering Post Support Bracket Drive Chain Tension...

  • Page 87: Polaris Products

    All-Season Grease at 500 miles (800 km) and annually or every 1000 miles (1600 km) thereafter. A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmo- biles. See page 134 for the part numbers of Polaris products.
  • Page 88 MAINTENANCE Lubrication EDGE 136 Rear Suspension (Indy 340 Touring) ✪ ✪ ✪ ✪ ✪ Edge Touring Rear Suspension ✪ ✪ ✪...
  • Page 89 MAINTENANCE Lubrication WideTrak Rear Suspensions ✪ ✪ ✪ ✪ ✪...

  • Page 90: Jackshaft Bearing

    MAINTENANCE Lubrication Jackshaft Bearing ✪ Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fit- ✪ ting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pumps).

  • Page 91: Throttle Cable

    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.

  • Page 92: Gearcase Oil Level (Widetrak)

    (2) every 500 miles (800 km) and whenever checking or changing lubricant. CAUTION Mixing brands or using non-recommended lubricants could result in exces- sive wear to chain, sprockets and bearings. Always use Polaris-recom- mended products for your vehicle. MAINTENANCE...

  • Page 93: Chaincase Oil

    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 134 for the part numbers of Polaris products.

  • Page 94: General Maintenance

    General Maintenance Spark Plugs A new engine can cause temporary spark plug fouling due to the preser- vative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your machine.
  • Page 95 MAINTENANCE General Maintenance Spark Plugs 1. 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. NOTE: The tip should not be white.

  • Page 96: Intake Filters

    General Maintenance Intake Filters CAUTION Operating the snowmobile with the intake filters removed may cause carbu- retor icing. The result will be poor fuel economy or carburetor malfunction. Always reinstall the intake filters before operating the snowmobile. The intake foam filter (✪) limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow.

  • Page 97: Oil Filter

    MAINTENANCE General Maintenance Fuel Filter/Fuel Lines See your Polaris dealer for replacement of the in-tank fuel filter every 1000 miles (or annually). Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fuel compounds may occur.

  • Page 98: Carburetor Adjustments

    CAUTION 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.

  • Page 99: Water/Sediment Trap Service

    General Maintenance Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sedi- ment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained at least every 2000 miles (3200 km) and inspected for contamination.

  • Page 100: Exhaust System

    Maintenance of the VES is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles (800-1600 km), bring the machine to an authorized Polaris dealer to have the VES disassem- bled, inspected, and cleaned. NOTE: To ensure maximum performance and minimize required main- tenance, follow the oil recommendation chart on page 62.
  • Page 101 Do not dilute with water. Never exceed a 60% antifreeze/ 40% water mixture. Contact your dealer if greater protection is required. See page 134 for the part numbers of Polaris products. NOTE: Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.

  • Page 102: Coolant Level

    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.

  • Page 103: Bleeding The Cooling System

    MAINTENANCE General Maintenance Bleeding the Cooling System WARNING Steam and hot liquids will cause serious 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.
  • Page 104 General Maintenance Bleeding the Cooling System CAUTION 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. Surge Tank Models Perform the bleeding procedure when the engine is cold.

  • Page 105: Drive Chain Tension

    MAINTENANCE General Maintenance Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. 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.

  • Page 106: Brake Components

    Always replace brake pads when the brake pad material becomes thinner than the backing plate (approximately 1/16 Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, bring the machine to an authorized Polaris dealer for inspec- tion and adjustment. Brake Components 1. Brake Caliper 2.

  • Page 107: Brake Fluid

    Add the recommended brake fluid to bring the level up to the top of the fluid level mark on the inside of the reservoir. Replace brake fluid at least every two years with Polaris DOT 3 high temperature brake fluid. See page 134 for the part numbers of Polaris products.

  • Page 108: Bleeding The Hydraulic Brake System

    General Maintenance 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.

  • Page 109: Headlight Adjustment

    MAINTENANCE General Maintenance Headlight Adjustment The headlight may be adjusted for vertical aim using the following pro- cedure. 1. Place the snowmobile on a level surface with the headlight approxi- mately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall.

  • Page 110: Headlight Bulb Replacement

    General Maintenance NOTE: 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.

  • Page 111: Taillight/Brakelight Replacement

    MAINTENANCE General Maintenance Taillight/Brakelight Replacement 1. Remove the rear storage cover (1) if equipped. 2. Depending on your model, remove the screws (2) securing either the taillight housing (3) or the lens cover (4). 3. Remove and replace the bulb (5). 4.

  • Page 112: Clutch System

    Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. CAUTION 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. MAINTENANCE...

  • Page 113: Clutch Alignment Offset

    Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Other belts may match the dimensions, but can...

  • Page 114: Drive Belt Condition

    MAINTENANCE General Maintenance n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist.

  • Page 115: Drive Belt Removal

    MAINTENANCE General Maintenance Drive Belt Removal CAUTION Do not attempt to remove the drive belt after operating in reverse. The snow- mobile must be stopped after forward motion to prevent damage to compo- nents during belt removal. 1. Stop the engine after operating in a forward motion. 2.

  • Page 116: Drive Belt Installation

    General Maintenance Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rota- tion by positioning the identification numbers so that you can read them.

  • Page 117: Drive Belt Deflection

    MAINTENANCE General Maintenance n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pres- sure while measuring at point 2. This measurement should be 1 1/4I (3.2 cm).

  • Page 118: Torque Stop

    General Maintenance Torque Stop If your snowmobile is equipped with an engine torque stop, periodi- cally check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be .010I-.030I (.25-.75mm) from the engine case. Adjust if necessary, and lock the jam nut.

  • Page 119: Tool Kit

    Maintain the proper chain tension as outlined on page 102. 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. Tool Kit A tool kit is included with each machine for emergency and routine maintenance.

  • Page 120: Track Inspection

    Track Maintenance Track Inspection WARNING Broken track rods can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snow- mobile off the ground.

  • Page 121: Track Tension

    MAINTENANCE 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 mov- ing parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment is critical for proper handling.
  • Page 122 Track Maintenance Track Tension 4. 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 118. If the track needs adjustment: 5. Loosen the rear idler shaft bolt.

  • Page 123: Track Alignment

    MAINTENANCE Track Maintenance n 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. 1. Safely support the rear of the machine with the track off the ground. 2.
  • Page 124 Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary. EDGE IFS WideTrak ✪ ✪ ✪ ✪ ✪ ✪ ✪ ✪ MAINTENANCE ✪ ✪ ✪ ✪ ✪...

  • Page 125: Ski Alignment

    Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski align- ment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.

  • Page 126: Ski Skags

    Steering System n 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.

  • Page 127: Rail Slide Wear

    MAINTENANCE Steering System 7/16 n Rail Slide Wear (1.1 cm) Measure slide thickness at sev- eral points along the rail. Have your dealer replace the slide Minimum Thickness when it's worn down to the mini- All Except WideTrak mum thickness. Do not operate the snowmobile if slide thickness measures less.

  • Page 128: Pre-Ride Suspension Inspection

    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 follow- ing items on a weekly basis or before any long trip: Check suspension mounting bolts for tightness.

  • Page 129: Cleaning And Preservation

    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 134 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts.

  • Page 130: Clutch And Drive System

    Remove the drive belt and store in a cool dry location. To prevent oxi- dation on the clutch sheaves, lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant. NOTE: After storage, always use acetone or alcohol to remove the oil before reinstalling the drive belt.

  • Page 131: Engine And Carburetor Protection

    (BDC), the lowest position in the cylinder. On twin cylinder models, the opposite piston will be up. 5. Pour approximately two ounces of Polaris injector oil into the spark plug hole. 6. Wait one to two minutes and perform steps 3-5 on remaining cylin- ders.

  • Page 132: Electrical Connections

    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.

  • Page 133: Battery Fluid

    MAINTENANCE Battery Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks. WARNING Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing.

  • Page 134: Battery Removal

    Battery Battery Removal WARNING Improperly connecting or disconnecting battery cables can result in an explo- sion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. 1.

  • Page 135: Battery Installation

    MAINTENANCE Battery Battery Installation WARNING Batteries contain gases that can explode. If the battery vent tube is pinched or kinked, battery gases could accumulate. Whenever removing or installing the battery, disconnect the negative (black) cable first and reinstall the nega- tive cable last to avoid the possibility of explosion.

  • Page 136: Battery Storage

    Battery Battery Storage When your snowmobile is placed in storage for one month or more: • Remove the battery. • Charge it to the proper level. • Store it in a cool dry place. • Check and/or charge monthly. Before using the battery, take it to your dealer for testing and recharg- ing.

  • Page 137: Polaris Products

    POLARIS PRODUCTS Part No. 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (gal.) 2872347 Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.)

  • Page 138: 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 oper- Drive clutch binding ating RPM during acceleration or load variations Driven clutch mal- function Harsh drive clutch Drive belt worn or engagement...
  • Page 139 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive sys- Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain worn, sprocket teeth bro- Poor low RPM per- Worn drive belt formance Excessive belt/...

  • Page 140: Troubleshooting

    • Make sure fuel tank contains fuel. • Ice may be in fuel line, filter or pump. Add isopropyl alcohol to fuel system. On the standard Polaris carburetor, the choke will not function with the throttle depressed. See second item under Probable Cause" of Engine Contin- ually Backfires".
  • Page 141 TROUBLESHOOTING EDGE 136 Suspension (Indy 340 Touring) Problem Solution Rear suspension bot- • Increase torsion spring preload toms too easily • Increase rear shock compression damping by turning • Increase torsion spring wire diameter (see your dealer) Rides too stiff in rear •...
  • Page 142 EDGE Touring Suspension (ETS) Problem Solution Rear suspension bot- • Adjust RCA forward (see setup decal under hood). toms too easily • Adjust coil over spring on front track shock to increase • Adjust torsion spring blocks to highest position. •...

  • Page 143: Drive Belt Troubleshooting

    TROUBLESHOOTING Drive Belt Troubleshooting Causes Driving at low RPM Insufficient warm-up Towing at low RPM Riding with high RPM and slow speed (8000 RPM/10 MPH) Ice and snow build-up between track and tunnel Poor engine performance Loading machines onto trailers Clutch malfunction Slow, easy clutch engage- ment...

  • Page 144: Warranty

    Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information con- tained in this manual. Contact your Polaris dealer for replacement parts, ser- vice or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual.
  • Page 145 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. Polaris warranty will aid in notifying the proper owner when a unit is recovered.

  • Page 146: Limited Warranty

    WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty.

  • Page 147: Engine Oil

    How to Obtain Warranty Service If your snowmobile requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris snowmobiles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (The cost of trans- portation to and from the dealer is YOUR responsibility).
  • Page 148 In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty.
  • Page 149 Polaris snowmobile dealers in North America and is transfer- able 120 days after the original purchase date, free of charge, through any Polaris snow- mobile dealer. Coverage on Snow Check units is automatic. Although you do not receive a warranty card, your dealership should have printed a copy of the warranty reg- istration form.
  • Page 150 • Failures caused due to improper adjustments. • Failure due to unauthorized service. • Failures due to lack of service as required in the owner's manual or Polaris updates. This includes off-season storage as listed in the owner's manual. • Failure due to use of unauthorized parts or modifications.
  • Page 151 This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions.
  • Page 152 If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
  • Page 153 Environmental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068. Polaris warrants that the engine is free from defects in materials and workmanship that would cause it to fail to meet these regulations. The warranty period for this emissions...
  • Page 154 Polaris. Owners are responsible for performing the scheduled maintenance identified in the owner's manual. Polaris can deny an emissions warranty claim if any specified critical emissions-related maintenance is not performed. Performance of other scheduled main- tenance is strongly recommended, but is not necessary to keep the emissions-related warranty valid.

  • Page 155: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES TECHNICIAN (KM) 150 mi.
  • Page 156 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 157: Index

    INDEX Accessories ....49 Air Pollution ....5 Airbox Warning .
  • Page 158 Passenger Warning ... . . 23 Polaris Products ....134 Preload, Front Shock Spring..33 Premium Fuel Switch .

  • Page 159: Index

    INDEX Spark Plug Condition... 91 Spark Plug Removal ... 92 Spark Plugs ....91-92 Speed .

This manual is also suitable for:

Indy 340 touring600 edge touring 2006Indy 340 touring 2006Trail touring 2006Widetrak 2006

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