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Troubleshooting
Related Manuals for Polaris 600 HO IQ
Summary of Contents for Polaris 600 HO IQ
- Page 2 For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone (763) 417-8650 Fax (763) 542-0599 Part No. 9920459 Rev 02 Printed in USA...
- 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. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
- Page 4 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. RIDER SELECT is a trademark of Polaris Industries 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...
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Page 6: Table Of Contents
Polaris Products..... . . 122 Troubleshooting ..... . . 123 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: Operator Safety
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 Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. 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.
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Page 12: Riding Position
Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. -
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
Rider Capacity Your Polaris snowmobile is designed for a single rider only. Do not carry a passenger. Excessive Speed High speed driving, especially at night, could result in serious injury or death. -
Page 15: 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 16 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.
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Page 17: Ice And Snow Build-Up
SAFETY Operator Safety Ice and Snow Build-up 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 18: Driving Downhill
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 19: Driving In Hilly Terrain
SAFETY Operator Safety Driving in Hilly Terrain 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 20: Drive Belt
SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do not operate the engine with the intake silencer or filter removed. -
Page 21: Inadequate Snow Conditions
SAFETY Operator Safety Inadequate Snow Conditions Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. 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 machine. -
Page 22: Driving Responsibly
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 23 SAFETY 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...
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Page 24: 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 25: Track Warning
SAFETY Safety Decals and Locations Track Warning The track warning decal is on the rear of the tunnel: Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. -
Page 26: Reverse Warning
Safety Decals and Locations Reverse Warning The reverse warning decal is located on the console below the wind- shield: WARNING Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always: •... -
Page 27: Safety Decals And Locations
• 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 28: Features
FEATURES 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Seat Storage Compartment 7. Taillights 8. Rear Bumper 9. Snow Flap 10. Suspension 11. Track 12. Console Storage Compartment (if equipped) 13. Skis 14. Nosepan 15. Front Bumper... -
Page 29: Features
FEATURES 1. Fuel Filler Cap 2. RIDER SELECT (if equipped) 3. Ignition Switch 4. Brake Lever 5. Headlight Adjuster 6. MFD Gauge 7. Engine Stop Switch 8. Throttle Control 9. Hood Hold Down Straps 10. Recoil Starter Handle 11. Choke Lever 12. -
Page 30: Features
RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system (if equipped) allows you to adjust the handlebar position to fit your style of riding. Setting Position Comfort 1, 2 Control 3, 4, 5 Attack 6, 7 Some aftermarket accessories (including windshields and cargo bags) may interfere with the handlebar. -
Page 31: Features
FEATURES RIDER SELECT Adjustable Steering System Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system. 1. Stop the snowmobile. 2. -
Page 32: Features
FEATURES Fuel Valve The fuel valve is located under the hood. Turn the fuel valve off when- ever the snowmobile is stored or parked. 1. Turn the valve clockwise to turn off the fuel supply. 2. Turn the valve counter-clock- wise to turn on the fuel supply. -
Page 33: Features
FEATURES Detonation Elimination Technology (D.E.T.) The DET system prevents damage to the engine from detonation while developing the maximum power of the engine safely. A detonation sen- sor monitors the engine and responds to detonation by automatically reducing the engine timing. This can result in decreased engine RPM and performance. -
Page 34: Features
Detonation Elimination Technology (D.E.T.) DET Troubleshooting Use this chart to determine causes and solutions for detonation. If none of these conditions exists and the sensor remains activated, see your Polaris dealer for diagnosis. Possible Cause Poor quality fuel Improper engine modifications... -
Page 35: Features
FEATURES Instrumentation MFD Component Identification Item 1 Analog Gauge (if equipped) 2 Digital Gauge 3 CHECK ENGINE Indicator 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval... -
Page 36: Mfd Settings
FEATURES Instrumentation MFD Settings With the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch ( ) has a MODE but- ton (top) and a SET button (bottom). Standard vs. Metric The MFD will display either stan- dard or metric units of measurement. -
Page 37: Features
FEATURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs: Per- formance, Engine and History. Each program will remain in the display until another is selected. Performance Program While in the Performance mode, press the SET button to cycle through the settings: odometer, Trip 1, Trip 2 and Trip F (if equipped with elec- tronic fuel gauge). -
Page 38: Features
FEATURES Instrumentation MFD Digital Display Programs Trip Settings Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled. 1. To reset a trip odometer to zero, enter the Trip 1 or Trip 2 display. 2. -
Page 39: Features
FEATURES Instrumentation MFD Digital Display Programs Engine Program The Engine Program automatically displays the engine coolant tempera- ture, engine hours, electrical system voltage level and fuel level (if equipped). On machines equipped with altimeter sensor and ambient air temperature sensors, altitude and ambient air temperature will display as additional screens in the engine program. -
Page 40: Features
Instrumentation MFD Digital Display Programs Engine Program Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. NOTE: Press and hold the MODE switch for ten seconds to switch between stan- dard and metric units of measure- ment. -
Page 41: Features
FEATURES Instrumentation MFD Digital Display Programs History Program The History Program automatically displays electrical system voltage level and fuel level. While in the History mode, press the SET button to view maximum vehicle speed, maximum engine rpm or the current service interval set- ting. -
Page 42: Features
Instrumentation MFD Digital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders. When the logged hours reaches the designated service interval (set by the user), the gauge provides a reminder that service is due. "SErVCE" will flash in the odometer area and "ENG"... -
Page 43: 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 44: Front Suspension Adjustments
Front Suspension Adjustments Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris dealer for assistance before attempt- ing to adjust preload. Increasing the spring preload too much may adversely affect the han- dling of the snowmobile and the performance of the rear suspension. - Page 45 THE PERFECT FIT Front Suspension Adjustments Shock Compression Damping (if equipped) Turn the adjustment knob to make adjustments to the compression damp- ing. The standard setting is 10 clicks from the full stop position. When adjusting, we recommend that you turn the knob only one click, then test ride.
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Page 46: 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 47: 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 48 Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension.
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Page 49: Torsion Spring Preload
THE PERFECT FIT IQ Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more effort. - Page 50 IQ Rear Suspension Adjustments Rear Shock Compression Damping (Premium Shocks) THE PERFECT FIT Turn the adjustment knob on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster slightly, then test ride.
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Page 51: Suspension Coupling
IQ Rear Suspension Adjustments 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 52 THE PERFECT FIT IQ Rear Suspension Adjustments 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.
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Page 53: Weight Transfer During Acceleration
THE PERFECT FIT IQ Rear Suspension Adjustments 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 conditions. To decrease weight transfer under acceleration (for improved corner- ing), rotate the RRSS to a higher... -
Page 54: Limiter Strap Position
THE PERFECT FIT SwitchBack Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information. The following information is provided only as a guideline to be used for initial suspension set-up. - Page 55 THE PERFECT FIT SwitchBack Rear Suspension Adjustments Rear Shock Compression Damping Turn the adjustment knob on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster slightly, then test ride.
- Page 56 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 •...
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Page 57: Handlebar Adjustments
THE PERFECT FIT Handlebar Adjustments When making handlebar adjustments, always be sure the handlebars, brake lever and throttle lever operate smoothly and do not contact the fuel tank, windshield or any other part of the vehicle when the handle- bars are turned fully to the left or right. Handlebar Angle Follow these steps to adjust handle- bar angle at the handlebar block. -
Page 58: Handlebar Position
THE PERFECT FIT Handlebar Adjustments Handlebar Position If your snowmobile is equipped with the RIDER SELECT feature, adjust handlebar position as outlined on page 27. For models with sta- tionary steering posts, adjust handlebar position as outlined below. Refer to the illustration on page 54. 1. -
Page 59: Traction Products
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 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 60: Wear Strips
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 61: Pre-Ride Inspections
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 ref- erenced 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 62: Before Starting The Engine
Before Starting the Engine 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 63: Brake Lever Travel
PRE-RIDE INSPECTIONS Before Starting the Engine n 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 64: Parking Brake Lever Lock
Before Starting the Engine n 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. 1. Brake Lever 2. - Page 65 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System 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.
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Page 66: Recoil Rope
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. -
Page 67: Start The Engine And Check
PRE-RIDE INSPECTIONS 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 equipped) If your machine has a tether switch, remove the tether from the switch to make sure the engine stops immediately. -
Page 68: Operation
Starting the Engine 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 59. Starting a Cold Engine Do not depress the throttle until the engine starts. -
Page 69: Starting A Warm Engine
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 70: Oil Injection System
This snowmobile is equipped with a variable exhaust system (VES). Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends the use of VES II 2 Cycle Oil for this engine. See page 122 for the part numbers of Polaris products. -
Page 71: Track Warm-Up
OPERATION Track Warm-Up 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 72 Fuel 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. •...
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Page 73: Fuel System Deicers
OPERATION Fuel For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor- mance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85). -
Page 74: Low Oil Indicator Light
Always maintain a visible level of oil in the tank. If oil is not visible, continued operation may cause serious engine damage. See page 67 for oil recommendations. The Polaris oil cap on the oil bottle is vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts. CAUTION... - Page 75 Either condition may be caused by improper carburetor adjustment. Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage. Always have your Polaris dealer perform any carburetor adjustments. WARNING...
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Page 76: 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 77: 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 78: 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. WARNING OPERATION... -
Page 79: Emergency Stopping
OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 74 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch Tether Switch (Option) WHAT IT DOES... -
Page 80: Emergency Starting
Emergency Starting If the recoil starter system fails, an emergency start strap is provided in the tool kit. 1. Open the hood. 2. Remove the left side panel. 3. Using the belt removal tool, follow the directions on the air box to relieve belt tension. 4. - Page 81 OPERATION Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. 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.
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Page 82: Daily Storage
Daily Storage At the end of each ride, park the snowmo- bile 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 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... -
Page 83: Maintenance
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 con- trol information (ECI) label and a factory-installed emissions informa- tion hangtag. -
Page 84: Emission Control Information
The speci- fied maintenance for the fuel filter is recommended additional emission- related maintenance. Polaris recommends that you contact an autho- rized Polaris dealer to perform any service that may be necessary. - Page 85 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. 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.
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Page 86: Item See Page
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 87: Ignition Switch
MAINTENANCE Periodic Maintenance Interval Table Item Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brake 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 88: Suspension Mounting Bolts
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 Drive Chain Tension Hood Latches Rear Wheel Idler Bolts Idler Bolt Jam Nut Rear Suspension Pivot... -
Page 89: Front Suspension
The front suspension does not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the suspension. -
Page 90: Throttle Cable
MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lightly with grease or oil. -
Page 91: Chaincase Oil
500 miles (800 km), then every 1000 miles (1600 km) or seasonally. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 122 for the part numbers of Polaris prod- ucts. Oil Check 1. Position the vehicle on a level sur- face. - Page 92 Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4) and drain the oil into a drain pan. Allow the oil to drain completely. 3. Clean off all metal shavings from the plug.
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Page 93: Spark Plugs
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 94: Spark Plug Condition
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. A hot exhaust system and engine can cause serious burns. -
Page 95: Oil Filter
MAINTENANCE Spark Plug Removal and Replacement 1. Remove the spark plug cap. 2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plug installation. 4. Torque to 18-22 ft. lbs. (24-30 Nm). 5. -
Page 96: Intake Filters
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 in-tank fuel filter every 1000 miles (or annually). Inspect the fuel lines regularly for signs of deterioration or damage. -
Page 97: Carburetor Adjustments
It's your dealer's responsibility to make sure the correct main jet is installed. 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 98: Cleaning Procedure
Carburetor Water/Sediment Trap 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 about every 1000 miles (1600 km) and inspected for contamination. -
Page 99: Cooling System
Please see your Polaris dealer. When adding or changing coolant, Polaris recommends using Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture. -
Page 100: Flushing The Cooling System
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 101: Bleeding The Cooling System
MAINTENANCE Cooling System Bleeding the Cooling System 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 102: Exhaust System
Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting. Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. -
Page 103: Drive Chain Tension
MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counter- clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. -
Page 104: Brake Components
3. Brake Pad Material (Replace when thickness is less than 1/16I/1.5 mm). Excessive Lever Travel Hydraulic brakes are self- adjusting, but if excessive brake pad clearance develops, bring the machine to an autho- rized Polaris dealer for inspec- tion and adjustment. MAINTENANCE WARNING... -
Page 105: Brake Fluid
If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 122 for the part numbers of Polaris products. -
Page 106: Bleeding The Hydraulic Brake System
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. 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. -
Page 107: Headlight Bulb Removal
MAINTENANCE Lights 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 108 Lights Taillight/Brakelight Replacement 600 HO IQ 1. Open the rear storage compart- ment. 2. Reach into the compartment and locate the socket assembly above the door opening. 3. Turn the socket counterclockwise 1/4 turn. 4. Carefully pull the socket assembly away from the taillight.
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Page 109: Clutch System
Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. 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. -
Page 110: Drive Belt Removal
Clutch System n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. -
Page 111: Drive Belt Installation
Drive Belt Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. Polaris recommends the use of O.E.M. belts. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor performance. -
Page 112: Drive Belt Deflection
Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4I (3.2 cm). -
Page 113: Track Inspection
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 Track Inspection Broken track rods can cause a rotating track to come off the machine, which could cause serious injury or death. -
Page 114: Track Lubrication
Track Maintenance Track Lubrication 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 peri- ods on ice and other surfaces that have little or no snow for lubrication. -
Page 115: Track Tension
MAINTENANCE Track Maintenance 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 116 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 112. If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6.
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Page 117: Track Alignment/Condition
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 118: Steering System
MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary. -
Page 119: 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 120: Ski Skags
Steering System n Ski Skags 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 121: Rail Slide Wear
MAINTENANCE Steering System n Rail 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 ( ). Do not operate the snowmobile if slide thickness measures less than 7/16I (1.1 cm). -
Page 122: 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 122 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 123: Clutch And Drive System
MAINTENANCE Extended Storage Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual. -
Page 124: Electrical Connections
Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts. Track and Suspension Moderate track tension should be maintained during summer storage. -
Page 125: 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 126: 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 Driven clutch mal- acceleration or load function variations Harsh drive clutch Drive belt worn or engagement... - Page 127 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 128 Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails Faulty ignition to start No fuel to engine Poor engine com- pression Engine lacks power Fouled or defective spark plug(s) Fuel filter (loss of high RPM power) Incorrect clutching Carburetor and fuel pump Engine continually Faulty plug(s)
- Page 129 TROUBLESHOOTING IQ Suspension Troubleshooting Problem Solution Rear suspension bot- • Adjust torsion spring preload to achieve proper static sag toms too easily • Change torsion spring to stiffer optional spring (see your • Revalve rear track shock (see your dealer). Rides too stiff in rear •...
- Page 130 SwitchBack Suspension Troubleshooting Problem Solution Rear suspension bot- • Set static sag (see page 45). Adjust torsion spring blocks toms too easily • Increase shock compression damping (see page 47). Rides too stiff in rear • Check for binding suspension components and grease all •...
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Page 131: 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 132: 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 133 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.
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Page 134: 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 135: 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 transpor- tation to and from the dealer is YOUR responsibility). - Page 136 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 137 • 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 138 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 139 Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068 at the time of sale to the ultimate purchaser. Polaris warrants that the engine is free from defects in materials and workmanship that may keep it from meeting these regulations.
- Page 140 Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Polaris recom- mends that you contact an authorized Polaris dealer to perform any service that may be necessary.
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Page 141: 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 142 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
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Page 143: Index
INDEX Accessories ....53 Adjustable Headlights ... 29 Adjustable Steering System..27-28 Air Pollution . - Page 144 Parking Brake Lever Lock ..61 Polaris Products ....122 Pre-Ride Checklist ....58 Pre-Ride Suspension Inspection .
- Page 145 INDEX Studs ......56 Survival Preparation ... . 10 Suspension Coupling, IQ .