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Troubleshooting
Related Manuals for Polaris 600 IQ Racer
Summary of Contents for Polaris 600 IQ Racer
- Page 3 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 4 All-terrain vehicles (ATVs) RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...
- Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
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Page 6: Table Of Contents
......This section defines your role, and your dealer’s role, in your snowmobile’s regular maintenance. Polaris Products Troubleshooting This section is a quick reference guide to solving problems. -
Page 7: Introduction
INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold. When teaching inexperienced operators to ride, set up a predetermined course for practice. -
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 welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others. -
Page 9: Vehicle Identification Numbers
INTRODUCTION Vehicle Identification Numbers Record your snowmobile’s identification numbers in the spaces provided. Vehicle Model Number: Tunnel VIN: (lower right side of the tunnel) Engine Serial Number: (right front side of engine crankcase) -
Page 10: Safety
Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. -
Page 11: 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 12: Riding Apparel
Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. -
Page 13: 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 14: 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 15: Disabled Operators
Rider Capacity Your Polaris snowmobile is designed for a single rider only. Do not carry a passenger. 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. -
Page 16: Ice And Snow Build-Up
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. You don’t have to be snowmobiling on a slope for an avalanche to occur. -
Page 17: Driving Downhill
SAFETY Operator 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 second your machine travels. -
Page 18: Driving In Hilly Terrain
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 19: 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 20: Inadequate Snow Conditions
Operator Safety Inadequate Snow Conditions WARNING 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 21: Driving Responsibly
SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers. - Page 22 Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART (°F) Wind Speed Calm Frostbite in >> WIND CHILL CHART (°C) Wind Speed Calm Frostbite in >> Actual Thermometer Reading (°F) Equivalent Temperature (°F) 30 min.
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Page 23: Safety Decals And Locations
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 24: Track Warning
SAFETY Safety Decals and Locations Track Warning The track warning decal is located on the rear of the tunnel: Passenger Warning This snowmobile is designed for one operator only. A “No Passenger” warning decal is located on the lower console:... - Page 25 SAFETY Safety Decals and Locations Operation Warning...
- Page 26 SAFETY Safety Decals and Locations Operation Warning...
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Page 27: Features And Controls
8. Recoil Starter Handle 9. Fuel Filler Cap 10. Park Brake Lock 11. Headlight Dimmer Switch 12. Handlebar Grip Warmer/ Thumbwarmer Switch 13. Tether Switch 14. Master Cylinder 15. Dragont Ignition System Switch (600 IQ Racer) or Electronic Reverse Button (600RR) - Page 28 1. Handlebar 2. Windshield 3. Headlight 4. Hood 5. Nosepan 6. Skis FEATURES AND CONTROLS 7. Track 8. Suspension 9. Snow Flap 10. Taillights 11. Seat...
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Page 29: Dragon Mode Facts
Be sure that the clutch engages at 5300 RPM or above to prevent forward creep of the vehicle. See your dealer if the clutch needs ad- justment. Please refer to the Polaris jetting chart and use the recommended jet for current temperatures as this system is sensitive to jet changes. -
Page 30: Dragon Mode Operation
Polaris DRAGON Ignition System (600 IQ Racer) DRAGON Mode Operation 1. Warm up the engine and track. See page 54. 2. When staged at the starting line, depress and hold the DRAGON button on the left handlebar (1). 3. Slowly advance the throttle... - Page 31 FEATURES AND CONTROLS Electronic Reverse (PERCt) (600RR) 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 ignition setting as described below. Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse.
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Page 32: Reverse Kit Maintenance
Electronic Reverse (PERCt) (600RR) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the reverse button for one second and release. The engine will slow and begin to rotate forward. The light on the tachometer will shut off. -
Page 33: The Perfect Fit
THE PERFECT FIT IQ 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 Absorber Components
IQ Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 92 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spring is set is called spring preload. -
Page 35: Front Shock Spring Preload
THE PERFECT FIT IQ Front Suspension Adjustments Front Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. A = Low preload B = High preload Increasing the spring preload too much... -
Page 36: 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... -
Page 37: Suspension Performance Tips
When riding on ice or hard-packed snow, adding a set of bogie wheels to the rail may enhance the machine’s performance. Bogie wheel kits are available from your dealer. Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. NOTE: Keep the suspension pivot points lubricated. - Page 38 THE PERFECT FIT IQ Rear Suspension Adjustments Rear 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. Contact your dealer for more information.
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Page 39: Suspension Coupling
THE PERFECT FIT 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 suspension coupling, these torque arms could move independently of each other. - Page 40 IQ 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 independent movement between the rear torque and the front torque arm.
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Page 41: Weight Transfer During Acceleration
THE PERFECT FIT IQ Rear Suspension Adjustments Weight Transfer During Acceleration IQ Rear Rear Scissor Stop (RRSS) The preferred method for controlling weight transfer during acceleration of the IQ rear suspension is by adjusting the RRSS. Use the scissor stop tool (1) located in your tool kit to make the adjustments. -
Page 42: Handlebar Adjustments
Handlebar Adjustments Handlebar with Riser Block 1. Remove the handlebar cover to expose the handlebar mounting hardware. 2. Using a 1/4” Allen wrench, loosen the two bolts on the bottom of the riser or the two bolts on the top of the riser, depending on the type of adjustment required. - Page 43 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. See your dealer for a complete list of accessories. Use only Polaris parts and accessories on your Polaris snowmobile.
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Page 44: Traction Products
Accessories Traction Products Another way to tailor your machine is to install traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. NOTE: Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. - Page 45 Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products. WARNING Loss of control can result in serious personal injury or death. Proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard-packed snow or ice.
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Page 46: Wear Strips
Accessories Wear Strips Polaris IQ models are manufactured with tunnel wear strips or wear strip coolers installed. To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Wear strips are designed for a specific stud length. See your dealer’s studding chart for recommended traction accessories. -
Page 47: 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 referenced 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 48: Before Starting The Engine
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. We’ve attempted to provide as much information as possible to alert you to the safety requirements of snowmobiling. -
Page 49: Hydraulic Brakes
PRE-RIDE INSPECTIONS Before Starting the Engine Hydraulic Brakes Always check the following items to assure proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2″ (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. -
Page 50: Parking Brake Lever Lock
Before Starting the Engine Parking Brake Lever Lock Your snowmobile may have a parking brake lever lock located over the brake lever. 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. -
Page 51: Track Inspection
Check 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 52: Start The Engine And Check
Start the Engine and Check 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 45. n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. -
Page 53: Operation
They 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 99 for the part numbers of Polaris products. 600 IQ Racer 600RR... -
Page 54: Fuel Recommendations
Always use premium non-oxygenated (92 octane) fuel. 600RR Fuel Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance 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 55 OPERATION Engine Break-In Fuel Recommendations WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not overfill the tank. Do not fill the tank neck. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
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Page 56: Starting The Engine
Starting the Engine Starting a Cold Engine Do not depress the throttle until the engine starts. 1. Attach the tether cord to the tether switch. 2. Pull the kill switch (shut-off switch) up to RUN. 3. Flip the choke toggle to FULL CHOKE. 4. - Page 57 OPERATION Engine and Track Warm-Up WARNING A loose track or flying debris could cause serious personal 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.
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Page 58: Slide Rail And Track Cooling
Always maintain a visible level of oil in the tank. If oil is not visible, continued operation may cause serious engine damage. See page 50 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. OPERATION... -
Page 59: Jetting Guidelines
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. Jetting Guidelines Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. -
Page 60: Engine Stop Switch
n Engine Stop Switch Push down on the engine stop switch (1) to stop the engine in an emergency. To restart the engine, pull the switch up to the ON position. Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. -
Page 61: Daily Storage
OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4″ (10 cm) off the ground. Cover the machine with an appropriate cover. -
Page 62: Maintenance
Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 91 (R+M)/2 for the 600 IQ Racer and 87 (R+M)/2 for the 600RR. The emission control system designation per SAE J1930 is EM. - Page 63 Personal safety is critical when attempting to service or adjust your snowmobile. If you’re not familiar with safe service or adjustment procedures and the use of tools, or if you don’t feel comfortable performing these tasks yourself, contact an authorized Polaris dealer for service. CAUTION Hot components can cause damage to plastic.
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Page 64: Drive Belt Condition
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 Offset Alignment... -
Page 65: Auxiliary Shut-Off Switch (Engine Stop Switch)
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 (600RR) (synchronize) Throttle Cable Choke Cable Vent Lines Throttle Position Sensor Choke... -
Page 66: Suspension Mounting Bolts
Periodic Maintenance Interval Table Item Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Suspension Shock Oil Cooling Fins and Shroud Skags (Wear Bars) Ski Saddle/Spindle Bolts Ski Pivots Ski Spindle Steering Post U-Joint Steering Arm(s) Upper / Lower Steering Post Support Bracket Drive Chain Tension Hood Straps... -
Page 67: Rear Suspension
(800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmobiles. See page 99 for the part numbers of Polaris products. -
Page 68: Front Suspension
Lubrication Front Suspension Two components of the IQ front suspension and steering require lubrication. Grease the left and right spindles. Raise the front end of the ma- chine to permit better grease entry into the spindle area. Lubricate the steering post U-joint. Throttle Cable Lubricate the throttle cable (1) lightly with grease or oil. -
Page 69: Chaincase Oil Level
“safe” marks on the dipstick (A). Add Polaris synthetic chaincase oil through the dipstick opening. Do not overfill. See page 99 for the part numbers of Polaris products. Flush the chaincase after the first 500 miles, then every 1000 miles or seasonally. -
Page 70: Spark Plugs
Owner’s Manual Supplement for specific information. Spark plug torque is 18-22 ft. lbs. (24-30 Nm). Always carry spare spark plugs in case of an emergency. CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. MAINTENANCE... - Page 71 MAINTENANCE Spark Plugs 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. WARNING A hot exhaust system and engine can cause serious burns.
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Page 72: Intake Filter
Intake Filter The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filters periodically to remove any accumulation of snow. CAUTION Operating the snowmobile with the intake filters removed may cause carburetor icing. -
Page 73: Fuel Pump
Variable Exhaust System (VES) 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 disassembled, inspected, and cleaned. NOTE: To ensure maximum performance and minimize required maintenance, follow the oil recommendations on page 50. -
Page 74: 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 75: 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 76: Coolant Mixture
Engine Cooling Coolant Mixture The coolant supplied in the system is a 50/50 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing at temperatures to -34° F (-37° C). If greater protection is required, the percentage of antifreeze to water may be increased. -
Page 77: Flushing The Cooling System
50/50 or 60/40 mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile. WARNING Steam and hot liquids will cause serious burns to your skin. -
Page 78: Bleeding The Cooling System
Engine Cooling Bleeding the Cooling System 3. Tip the snowmobile slightly onto its right side. Cycle the RPM from idle to enough RPM (4000) to get coolant to flow, but not enough to engage the clutch. This allows air to bleed from the rear crossover tube. -
Page 79: Drive Chain Tension
MAINTENANCE Drive Chain Tension 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. 2. Loosen the adjuster bolt jam nut (A). -
Page 80: Hydraulic Brake Inspection
n Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Squeeze the brake lever. It should move no closer to the handgrip than 1/2″ (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 80. -
Page 81: Brake Components
5. Brake Pad Material (Replace when thickness is less than 1/16″). Excessive Brake Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as described on page 77, the machine should be returned to an authorized Polaris dealer for inspection and adjustment. -
Page 82: Brake Fluid
Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately. 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 99 for the part numbers of Polaris products. MAINTENANCE... -
Page 83: 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 84: Headlight Adjustment
Headlights Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure: 1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall. - Page 85 MAINTENANCE Headlights 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. Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer.
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Page 86: 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. -
Page 87: Drive Belt Removal
MAINTENANCE Clutch System Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare belt. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. Drive Belt Removal CAUTION Do not attempt to remove the drive belt after operating in reverse. -
Page 88: Drive Belt Adjustment
Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4”. Drive Belt Adjustment 1. -
Page 89: Torque Stop
MAINTENANCE Torque Stop If your snowmobile is equipped with an engine torque stop (1), periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be a minimum of .010″ to a maximum of .030″ from the engine case (2). Adjust if necessary, and lock the jam nut. -
Page 90: Tool Kit
A tool kit is included with each machine for emergency and routine maintenance. Always keep the tool kit with the snowmobile. NOTE: The tools and maintenance items mentioned in this book, as well as a long line of other Polaris accessories, are available at your Polaris dealer. MAINTENANCE... -
Page 91: Track Tension
7. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track. Track Tension Data Model 600 IQ Racer 600RR weight Weight Measurement Location 10 lbs. (4.54 kg) 16″ ahead of rear idler shaft 10 lbs. -
Page 92: Track Alignment
Track Maintenance f the track needs adjustment (continued): 8. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new. 9. Start the machine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brakes). 10. -
Page 93: Track Lubrication
MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods are a serious safety hazard. They 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. -
Page 94: Steering System
MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all fasteners and tighten if necessary. Specifically check fasteners marked with a... -
Page 95: 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 alignment 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 96: Ski Skags
Steering System Ski Skags WARNING Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice. -
Page 97: Suspension Maintenance
MAINTENANCE Suspension Maintenance 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 (A). Do not operate the snowmobile if slide thickness measures less than 7/16″... -
Page 98: Cleaning And Preservation
Remove the drive belt and store in a cool dry location. Lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant. See page 99 for part numbers. Do not lubricate clutch components, except the driven clutch shaft bushing as... -
Page 99: Engine And Carburetor Protection
See page 99. Always add Premium Carbon Clean or a fuel conditioner/stabilizer to the fuel tank. See page 99 for the part numbers of Polaris products. Follow the instructions on the can, running the engine for five minutes to get additives through the entire fuel system. -
Page 100: Electrical Connections
Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. See page 99 for the part numbers of Polaris products. 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 101: Transporting The Snowmobile
MAINTENANCE Transporting the Snowmobile Whenever the snowmobile is transported: 1. Turn the fuel valve clockwise to OFF to shut off the fuel supply (1). Turn the valve counter-clockwise to ON to turn the fuel supply on (2). NOTE: The fuel valve is located under the hood. -
Page 102: Polaris Products
Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid (12 oz.) 2872893 Engine Degreaser (12 oz.) 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carb and Throttle Body Cleaner POLARIS PRODUCTS... -
Page 103: Troubleshooting
TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Erratic engine Drive clutch binding operating RPM during accelera- tion or load Driven clutch variations malfunction Harsh drive Drive belt worn or clutch... - Page 104 Engine Troubleshooting Problem Probable Cause Noise in drive Broken drive clutch system components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose or worn, sprocket teeth broken Poor low RPM Worn drive belt performance Excessive belt/sheave clearance...
- Page 105 -Make sure the fuel valve is “ON”. Check tank level and fill up with correct fuel. -Ice in fuel line, filter, or pump. On the standard Polaris carburetor, the choke will not function with the throttle depressed. See second item under “Probable Cause” of “Engine continually backfires”.
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Page 106: Suspension Troubleshooting
Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension -Increase torsion spring preload -Increase rear shock compression damping by turning screw bottoms too easily clockwise -Increase torsion spring wire diameter (see your dealer) Rides too stiff in -Check for binding suspension shafts and grease all pivot points rear -Decrease torsion spring preload adjustments... -
Page 107: Belt Troubleshooting
TROUBLESHOOTING Belt Troubleshooting Belt Wear/Burn 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 en-... -
Page 108: Warranty
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. 5. Details of trouble experienced 6. -
Page 109: 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 110: 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 transportation to and from the dealer is YOUR responsibility). - Page 111 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 pre-delivery inspection (PDI) form prior to delivery may void the warranty.
- Page 112 S Failures caused due to improper adjustments. S Failure due to unauthorized service. S 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. S Failure due to use of unauthorized parts or modifications.
- Page 113 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 114 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.
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Page 115: Maintenance Record
MAINTENANCE RECORD DATE MILES/KM 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) TECHNICIAN SERVICE PERFORMED / COMMENTS... - Page 116 MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS...
- Page 117 MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS...
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Page 118: Index
Accessories ....Altitude Ignition Setting ..Avalanches ....Before Starting the Engine Belt Troubleshooting . - Page 119 ....Passenger Warning ....Polaris Products ....Pre-Ride Checklist .