Polaris 600 IQ Racer Owner's Manual
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Polaris 600 IQ Racer Owner's Manual

Polaris 600 IQ Racer Owner's Manual

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PMS 419
600 IQ Racer
Snowmobile Owner's Manual
for Maintenance and Safety

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  • Page 1 PMS 419 600 IQ Racer Snowmobile Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING 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. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 PMS 419 For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922855 Rev 01 Printed in USA *9922855...
  • Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.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 recreational products.
  • Page 6 POLARIS, THE WAY OUT, IQ and DRAGON are registered trademarks of POLARIS Industries Inc. Copyright 2010 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 7: Table Of Contents

    POLARIS Products..... 100 Troubleshooting ..... . . 101 Warranty .

  • Page 9: Introduction

    INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations.

  • Page 10: Preservation Of The Environment

    POLARIS snowmobiles are engineered to conform to these SAE stan- dards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others.

  • Page 11: Vehicle Identification Numbers

    INTRODUCTION Vehicle Identification Numbers Record your snowmobile's identification numbers in the spaces pro- vided. Vehicle Model Number: ___________________________________________________ Tunnel VIN: ____________________________________________________________ (right side of tunnel) Engine Serial Number: ____________________________________________________ (right front side of engine crankcase)

  • Page 12: 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 indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

  • Page 13: 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 14: Riding Position

    SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. WARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track.

  • Page 15: Riding Apparel

    Riding Apparel Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 16: Disabled Operators

    SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. WARNING! Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Do not allow disabled persons to operate this vehicle.

  • Page 17: Rider Capacity

    SAFETY Operator Safety Rider Capacity Your POLARIS snowmobile is designed for a single rider only. Do not carry a passenger. Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather.

  • Page 18: 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 19 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 20: Driving On Slippery Surfaces

    SAFETY Operator Safety Ice and Snow Build-up WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering.

  • Page 21: 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 22: Driving In Hilly Terrain

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

  • Page 23: Drive Belt

    SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. CAUTION! Operation of the engine with the belt removed may result in personal injury or damage to the engine. Any servicing that requires operation without a belt must be performed by your dealer.

  • Page 24: Inadequate Snow Conditions

    SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile. NOTICE: Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine.

  • Page 25: 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 26 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 Actual Thermometer Reading (_F) Speed -10 -15 -20 -25 -30 -35 -40 -45 Equivalent Temperature (_F) Calm -10 -15 -20 -25 -30 -35 -40 -45 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63...

  • Page 27: Safety Decals And Locations

    If any decal becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety decals are pro- vided by POLARIS at no charge. The part number is printed on the decal. Clutch Cover Warning...

  • Page 28: 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 29: Features

    FEATURES Safety Decals and Locations Operation Warning “No Passenger” Warning Track Warning...

  • Page 30: Features

    FEATURES 1. Headlight Dimmer Switch 9. Choke Control 2. Ignition Switch/Tether Switch 10. Hand/Thumbwarmer Switch 3. Master Cylinder 11. Brake Lever 4. Engine Stop Switch 12. Parking Brake Lock 5. Throttle Control 13. DRAGON Ignition System Switch 6. Recoil Starter Handle 14.

  • Page 31: Features

    • Be sure that the clutch engages at 5300 RPM or above to prevent for- ward creep of the vehicle. See your dealer if the clutch needs adjust- ment. • Please refer to the POLARIS jetting chart and use the recommended jet for current temperatures as this system is sensitive to jet changes.

  • Page 32: Features

    FEATURES POLARIS DRAGON Ignition System 1. Warm up the engine and track. 2. When staged at the starting line, depress and hold the DRAGON button on the left handlebar (1). 3. Slowly advance the throttle to the wide-open position while keeping the button depressed.

  • 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: Front Suspension Adjustments

    THE PERFECT FIT Front Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pres- sure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. To change front shock spring preload, grasp the spring and rotate it.

  • Page 35: Front Springs

    Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a POLARIS dealer. Shock Damping (Walker/Evans Shocks) Turn the adjuster clockwise to increase Adjuster stiffness.

  • Page 36: Rear Suspension Adjustments

    Bogie wheel kits are available from your dealer. • POLARIS offers track kits for improved flotation in deep snow. See your dealer for assistance. TIP: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.

  • Page 37: Torsion Spring Tension

    THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information. The following information is provided only as a guideline to be used for initial suspension set-up.

  • Page 38: Suspension Coupling

    THE PERFECT FIT 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 suspension coupling, these torque arms could move independently of each other.
  • Page 39 THE PERFECT FIT Rear Suspension Adjustments 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. Adjusting the RRSS either allows more weight to transfer to the rear for more traction, or allows less weight to transfer to the rear, resulting in improved cornering performance.

  • Page 40: Weight Transfer During Acceleration

    THE PERFECT FIT Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight trans- fer during acceleration is by adjusting the rear rear scissor stop. Use the scissor stop tool located in your tool kit to make the adjustments. To decrease weight transfer under acceleration (for improved cornering), rotate the stop to a higher position.

  • Page 41: Handlebar Adjustments

    3. Tighten the bolts. Accessories POLARIS offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only POLARIS parts and accessories on your POLARIS snowmo- bile. Use of unapproved parts and accessories may result in: •...

  • Page 42: 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 war- ranties are void if track damage or failure results from improper or excessive stud installation or the use of non-POLARIS traction prod- ucts.

  • Page 43: Wear Strips

    THE PERFECT FIT 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 44: 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 refer- enced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Item See Page Drive Belt Condition...

  • Page 45: Before Starting The Engine

    PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death.
  • Page 46 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 (1.3 cm) indicates low brake fluid level or air in the hydraulic system.
  • Page 47 PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock Parking Brake only when you want the machine Brake Lock Lever to remain stationary; for exam- ple, when parked on an incline for a period of five minutes or less.

  • Page 48: Steering System

    PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, which could cause loss of control resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering.

  • Page 49: Hood Latches

    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 50: Auxiliary Shut-Off Switch (Engine Stop Switch)

    PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Before Starting the Engine beginning on page 41.

  • Page 51: Operation

    OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. •...
  • Page 52 NOTICE: Use of any lubricants other than those recommended by POLARIS may cause serious engine damage. We recommend the use of POLARIS lubricants for your vehicle.

  • Page 53: Fuel Recommendations

    Oils may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All POLARIS oils are compatible with each other. See page 100 for the part numbers of POLARIS products. Recommended Oil...
  • Page 54 Never use deicers or additives containing methanol. POLARIS also recommends the use of Carbon Clean Plus. See page 100 for the part numbers of POLARIS products. TIP: When using oxygenated fuel containing ethanol, additional alcohol deicers or water absorbing additives should not be used.

  • Page 55: Starting The Engine

    OPERATION Starting the Engine CAUTION! To avoid personal injury and/or engine damage, do not operate the recoil pull-rope starter while the engine is running. Starting a Cold Engine Do not depress the throttle until the engine starts. 1. Attach the tether cord to the tether switch. 2.

  • Page 56: Emergency Stopping

    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 46 for more information about the engine stop switch. THROTTLE SYSTEM WHAT IT DOES CONDITION Brake Slows jackshaft Choke Floods engine Half throttle or less Engine Stop Switch Interrupts ignition circuit...

  • Page 57: Slide Rail And Track Cooling

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

  • Page 58: Low Oil Level

    Always maintain a visible level of oil in the tank. If oil is not visible, continued operation may cause serious engine damage. See page 49 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.
  • Page 59 Either condition may be caused by improper carburetor adjustment. CAUTION! Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage. Always have your POLARIS dealer perform any carburetor adjustments.

  • Page 60: Jetting Guidelines

    OPERATION 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 61: Daily Storage

    OPERATION 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. Cover the machine with an appropriate cover.

  • Page 62: Maintenance

    Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsi- ble for ensuring that the specified maintenance is performed. POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary.
  • Page 63 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. NOTICE: Hot components can cause damage to plastic. Always make sure the exhaust system and engine have cooled before tipping the snowmo- bile on its side for service or inspection.
  • Page 64 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 Frequency Page 150 mi.
  • Page 65 MAINTENANCE Periodic Maintenance Interval Table Item Frequency Page 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System 42, 76 Brake Fluid FUEL MANAGEMENT...
  • Page 66 MAINTENANCE Periodic Maintenance Interval Table Item Frequency Page 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season CHASSIS Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Suspension Shock Oil Cooling Fins and Shroud Drive Shaft Bearing...

  • Page 67: Front Suspension

    26. Rear Suspension Lubricate the suspension pivot shafts with POLARIS Premium All Sea- son Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 59 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

  • Page 68: 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 69 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 100 for the part numbers of POLARIS products. Oil Check 1. Position the vehicle on a level surface.

  • Page 70: 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. • Use recommended spark plugs with the proper gap. See your Owner's Manual Supplement.
  • Page 71 MAINTENANCE Spark Plugs Spark Plug Condition Normal The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. TIP: The tip should not be white.

  • Page 72: Intake Filters

    Variable Exhaust System (VES) Maintenance of the VES is limited to a periodic inspection and cleaning of system components. Bring the machine to an authorized POLARIS dealer to have the VES disassembled, inspected and cleaned at the inter- vals outlined in the maintenance charts beginning on page 59.

  • Page 73: Fuel Pump

    Do not attempt to service the fuel pump. Fuel Filter/Fuel Lines See your POLARIS dealer for replacement of the fuel filter every 1000 miles (1600 km), or annually. Inspect the fuel lines regularly for signs of deterioration or damage.

  • Page 74: Carburetor Adjustments

    It's your dealer's responsibility to make sure the correct main jet is installed. NOTICE: Operating the snowmobile with incorrect jetting can result in serious engine damage. Have your POLARIS dealer perform all carburetor adjustments to ensure all adjustments are done correctly. Carburetor Adjustments The frequency at which the carburetors are synchronized or balanced is important.
  • Page 75 MAINTENANCE Carburetor Water/Sediment Trap Service Drain the water/sediment traps located at the bottom of each carburetor about every 1000 miles (1600 km). Inspect for contamination. WARNING! When draining the traps, fuel spillage will occur. Always work in a well ventilated area away from anything that may cause the fuel to ignite, such as open flames, sparks, heaters, trouble lights, cigarettes, etc.

  • Page 76: Cooling System

    Please see your POLARIS dealer. When adding or changing coolant, POLARIS recommends using Pre- mium 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 77: 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 78 MAINTENANCE Cooling System Bleeding the Cooling System NOTICE: If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced. If coolant becomes low in the tank, bleed the system of trapped air. Per- form the bleeding procedure when the engine is cold.

  • Page 79: Exhaust System

    MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.

  • Page 80: Hydraulic Brake Inspection

    (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 inspection and adjustment. Brake Components 1. Brake Caliper 2.

  • Page 81: Brake Fluid

    Maintain the brake fluid level between the MIN and MAX marks on the master cylinder reservoir. Use only POLARIS DOT 4 high temperature brake fluid. See page 100 for the part numbers of POLARIS products. Replace brake fluid at least every two years.

  • Page 82: Bleeding The Hydraulic Brake System

    MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death.

  • Page 83: Headlight Adjustment

    MAINTENANCE Lights 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 84: Headlight Bulb Removal

    MAINTENANCE Lights Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb, clean it with an alcohol-moistened towel. Headlight Bulb Removal 1.

  • Page 85: Headlight Bulb Installation

    MAINTENANCE Lights Headlight Bulb Installation 1. Hold the bulb by its metal base and install it into the wire harness. 2. Insert the bulb into the housing. 3. Connect the spring to the housing. 4. Carefully flip the spring back into the housing, placing it around the wire harness.

  • Page 86: Clutch System

    POLARIS dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. NOTICE: The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated. Do not lubri- cate clutch bushings.

  • Page 87: Drive Belt Condition

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

  • Page 88: Drive Belt Removal

    MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse (if equipped). The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure forward engage- ment before attempting to remove the belt.

  • Page 89: Drive Belt Installation

    MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer cir- cumference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the break-in period.

  • Page 90: 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 WARNING Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts.

  • Page 91: Track Lubrication

    MAINTENANCE Track Maintenance Track Lubrication The slide rail needs snow for lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear. WARNING! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death.
  • Page 92 TRACK TENSION DATA CHART Measurement Suspension Slack Measurement Weight Location 600 IQ Racer 1 1/4"-1 1/2" (3.2-3.8 cm) 10 lbs. 16" (40 cm) (4.54 kg) ahead of rear idler shaft TIP: Tension adjustments should be made only after the track is warmed up and limber.

  • Page 93: Rear Wheel Idler Bolts

    MAINTENANCE Track Maintenance Track Tension 5. 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 If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7.

  • Page 94: 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 95 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary.     ...

  • Page 96: Ski Alignment

    WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment. 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 97: Skags (Wear Bars)

    MAINTENANCE 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 con- trol while turning on hard-packed snow or ice.

  • Page 98: Suspension Mounting Bolts

    MAINTENANCE Suspension Maintenance n 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 99: 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 100 for the part numbers of POLARIS products. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts.

  • Page 100: Clutch And Drive System

    Remove the drive belt and store in a cool dry location. To prevent oxida- tion on the clutch sheaves, lubricate the sheave faces of the drive and driven clutches with a light coat of oil or POLARIS Cable Lubricant. TIP: After storage, always use acetone or alcohol to remove the oil before rein- stalling the drive belt.
  • Page 101 (BDC), the lowest position in the cylinder. On twin cyl- inder 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 102: 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 103: Transporting The Snowmobile

    MAINTENANCE Extended Storage Transporting the Snowmobile Whenever the snowmobile is transported: 1. Turn the fuel valve clock- wise to OFF to shut off the fuel supply. Turn the valve counter-clockwise to ON to turn the fuel supply on. The fuel valve is located under the hood.

  • Page 104: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2873023 Synthetic 2-Cycle Racing Oil (gal./3.8 l) 2875035 Premium 2-Cycle Semi-Synthetic Oil (qt./.95 l) 2875036 Premium 2-Cycle Semi-Synthetic Oil (gal./3.8 l) 2875038 Premium 2-Cycle Semi-Synthetic Oil (2.5 gal./9.5 l) 2877882 VES Gold Plus 2-Cycle Oil (qt./.95 l)

  • Page 105: Troubleshooting

    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 Drive clutch binding • SEE YOUR DEALER. operating RPM Driven clutch • SEE YOUR DEALER. during acceleration malfunction or load variations...
  • Page 106 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch • SEE YOUR DEALER. system components Bearing failure/ • SEE YOUR DEALER. chaincase, jackshaft, or front drive shaft Drive belt surface • Inspect and replace as needed. flat spots Drive chain loose •...
  • Page 107 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails Faulty ignition • Install new spark plug(s). If engine to start still fails to start, check for spark. If there's no spark, SEE YOUR DEALER. No fuel to engine •...

  • Page 108: Suspension Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bot- • Adjust torsion spring preload (see page 33). toms too easily • Increase rear shock compression damping by turning screw clockwise. • Increase torsion spring wire diameter (see your dealer). Rides too stiff in rear •...
  • Page 109 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Front end pushes • Check for worn skags. • Adjust torsion spring preload (see page 33). • Check for binding front suspension shafts and steering components, grease all pivot points (elevate front of machine). • Increase IFS preload (if equipped) (see page 30). •...

  • Page 110: Drive Belt Troubleshooting

    TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up.

  • Page 111: Warranty

    WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty infor- mation contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile mainte- nance, which may supersede information contained in this manual.
  • Page 112 2. POLARIS warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. 3. POLARIS warranty will aid in notifying the proper owner when a unit is recovered...

  • Page 113: Limited Warranty

    WARRANTY Limited Warranty POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED 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 114: Engine Oil

    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 vehi- cle Pre-Delivery Inspection, perform all applicable service bulletins and have the con- sumer sign the PDI form prior to delivery may void the warranty.
  • Page 115 WARRANTY Conditions and Exclusions Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contamination. The following items are excluded from warranty con- sideration if the failure was due to wear or not the direct result of a defect: Skis Ski wear rods Tracks...
  • Page 116 How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your vehicle was purchased, War- ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle.
  • Page 117 You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and notices regarding your vehicle.
  • Page 118 This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 119 POLARIS dealer to perform any service that may be necessary for your vehi- cle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 120: 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 SERVICE PERFORMED / COMMENTS (KM) 150 mi.
  • Page 121 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 122 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 123: Index

    INDEX Accessories ....37 Disabled Operators ....12 Air Pollution .
  • Page 124 INDEX Handlebar Adjustments ..37 Parking Brake Lever Lock ..43 Handlebar Angle ....37 Passenger Warnings .
  • Page 125 INDEX Storage, Daily ....57 Traction Products ... . 38-39 Storage, Extended ... . 95-99 Transporting the Snowmobile .

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