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Polaris 600 IQ Widetrak Owner's Manual

Polaris 2014 model 600 iq widetrak snowmobile owner's manual
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PMS 419
600 IQ
Widetrak
Snowmobile Owner's Manual
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Summary of Contents for Polaris 600 IQ Widetrak

  • Page 1 PMS 419 600 IQ Widetrak 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 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 4 POLARIS and IQ are registered trademarks of POLARIS Industries Inc. Copyright 2013 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 discrep- ancies may result between the actual vehicle and the information presented in this publi- cation.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ......5 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual.

  • Page 7: 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 8: Preservation Of The Environment

    INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education cam- paign. We encourage state and provincial governments across the snow- belt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to pro- tect our environment.

  • Page 9: Vehicle Identification Numbers

    INTRODUCTION Vehicle Identification Numbers Record your snowmobile’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

  • Page 10: 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. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

  • Page 11: Operator Safety

    SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 75 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger.
  • Page 12 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 13: Survival Preparation

    SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.

  • Page 14: Eye Protection

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

  • Page 15: Rider Capacity

    SAFETY Operator Safety Rider Capacity Your snowmobile is designed for up to two riders. A decal on the console indicates that the vehicle is designed for one operator and one passenger only. WARNING! Operating improperly with a passenger could cause loss of control and result in serious injury or death.

  • Page 16: Cargo Capacity

    SAFETY Operator Safety Cargo Capacity See page 32 for cargo loading information. WARNING! Overloading the cargo carrier can cause loss of control resulting in severe injury or death. The maximum cargo carrier capacity is 75 lbs. (34 kg). Never exceed the cargo carrier capacity. Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills.

  • Page 17: Excessive Speed

    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 be alert and pay attention to the trail ahead. If your speed is 40 MPH (16 km/h), your snowmobile is traveling about 60 feet (18 m) per second.

  • 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 Downhill

    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 On Slippery Surfaces

    SAFETY Operator Safety Driving on Slippery Surfaces WARNING! Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard- packed snow reduces steering and braking control, which may result in loss of control and serious injury or death.

  • Page 22: 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 23: Operating In Deep Snow

    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 24: 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 25 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WIND CHILL 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 26: Clutch Warning

    SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protec- tion. Read and follow the instructions of the decals and other warnings on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile.

  • Page 27: Passenger Warning

    SAFETY Safety Decals and Locations Passenger Warning Snowmobiles designed for an operator and one passenger have a warn- ing decal on the console. For more information on operating with a pas- senger, see page 13. WARNING This vehicle is designed for operator and “ONE” passenger only. Track Warning WARNING Track...

  • Page 28: Reverse Warning

    SAFETY Safety Decals and Locations Reverse Operation Warning Warning Reverse Warning POLARIS snowmobiles equipped with standard reverse and will have this decal on the console: 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 29: Operation Warning

    SAFETY Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all POLARIS snowmobiles: 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.

  • Page 30: Features

    FEATURES 1. Nosepan 11. Taillights 2. Skis 12. Cargo Carrier 3. Front Bumper 13. Rear Bumper 4. Hood 14. Snow Flap 5. Headlight 15. Track 6. Windshield 16. Suspension 7. Mountain Bar 17. Passenger Grab Handle 8. Handlebar 18. Seat Latch 9.

  • Page 31: Features

    FEATURES 1. Glove Box 8. Thumbwarmer Switch 2. MFD Display 9. Throttle Control 3. Ignition Switch 10. Engine Stop Switch 4. Shifter 11. Electronic Reverse Button 5. Recoil Starter Handle 12. MFD Control Switch 6. Brake Lever 13. Headlight Dimmer Switch 7.

  • Page 32: Features

    FEATURES Backrest The backrest can be adjusted for rider comfort. Whenever making adjustments, always make sure all lock levers are securely locked before operating. Tip: If an adjustment is difficult, rotate the lock levers counter-clockwise to relieve tension, then make the adjustment. Always tighten the levers after adjusting.

  • Page 33: Features

    FEATURES Shifter Shifter For normal operation, place the transmission in high gear. When- ever towing or operating with a heavy load, place the transmission in low gear. See page 73. When operating in low gear, vehicle speed will be limited to protect the drive train.

  • Page 34: Features

    FEATURES 12-Volt DC Outlet Use the 12-volt DC outlet to power a global positioning sensor (GPS), heated helmet shield, utility light, cell phone or other accessories. The outlet is located on the console near the ignition switch. Cargo Carrier Whenever towing or operating with a heavy load, place the transmission in low gear.

  • Page 35: Features

    FEATURES Fuel Resistor This snowmobile is equipped with a feature that allows the engine con- troller to select the proper operating software based on the type of fuel being used. See pages 62-63 for fuel information and recommendations. Make sure the correct resistor is installed for your fuel choice as instructed below.

  • Page 36: Features

    FEATURES Detonation Elimination Technology (DET) The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate, flicker or flash momentarily.. Check Engine Light Status Indicates Solid or Flickering...

  • Page 37: Features

    FEATURES Instrumentation MFD Component Identification Item 1 Analog Gauge (if equipped) 2 Digital Gauge 3 Check Engine Indicator 4 High Temp Indicator 5 Brake Indicator 6 Reverse Indicator 7 High Beam Indicator Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage...

  • Page 38: Features

    FEATURES Instrumentation MFD Settings The MFD control switch allows you to set the MFD display to your pref- erences. The rocker switch has a MODE button (top) and a SET but- ton (bottom). Specific instructions are outlined on the following pages. MFD settings can be made with the engine running or with the engine off.

  • Page 39: Features

    FEATURES Instrumentation MFD Settings Speedometer/Tachometer If your model is equipped with both analog and digital displays, the speedometer and tachometer can be viewed in either display. If the ana- log display is set to show speedometer readings, the digital screen will automatically display the tachometer (option 1).

  • Page 40: Features

    FEATURES Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD pro- grams: Performance, Engine and History. Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycle through the program’s screens.
  • Page 41 FEATURES Instrumentation MFD Digital Display Programs Performance Program Trip Settings Trip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge. The fuel symbol and the last fuel bar on the MFD gauge (if equipped) will blink when the fuel level reaches 1/8 of a tank.

  • Page 42: Features

    FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting (if equipped) 1. Enter the Performance Program. 2. Press and release the SET button until the clock screen is active. 3. Press and hold the SET button for five seconds. 4.

  • Page 43: Features

    FEATURES Instrumentation MFD Digital Display Programs Engine Program Press and release the MODE button until the engine program screen is active. The default display for this screen includes engine hours, electri- cal system voltage level, fuel level (if equipped) and either engine cool- ant temperature, air temperature (accessory) or altimeter (accessory).

  • Page 44: Features

    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. 1. Enter the Engine Program. Tip: Press and hold the MODE switch for ten sec- onds to switch between standard and metric units of measurement.

  • Page 45: Features

    FEATURES Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active. This screen will always display electrical system voltage level and fuel level (if equipped). Press and release the SET button to cycle through the Maximum Vehicle Speed, Maximum Engine RPM and Service Interval Reminder screens.

  • Page 46: Features

    FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated 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.

  • Page 47: Features

    FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder To reset the reminder at a new interval: 1. Enter the History Program. 2. Press and release the SET button until the service interval screen is active. 3. Press and hold the SET button for five seconds, until the hours begin to flash.

  • Page 48: The Perfect Fit

    THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 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 49: Suspension Performance Tips

    THE PERFECT FIT Rear Suspension Adjustments Rider weight, cargo weight, riding style, trail conditions and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver the best performance for a given set of conditions. However, all suspen- sion designs and adjustments involve a compromise, or trade-off.

  • Page 50: Rear Suspension Adjustments

    THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the dis- tance 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.

  • Page 51: Torsion Spring Preload

    THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. This adjustment is easier to make if tension is relieved from the spring. Exercise extreme caution if you use this method of adjustment, and follow the steps below carefully.
  • Page 52 THE PERFECT FIT Rear Suspension Adjustments Limiter Strap Position (Ski Pressure) The following information is provided only as a guideline to High be used for initial suspension set-up. Your set-up may vary based on your desired riding style. High: Limiter strap in high position increases ski pressure Low: Limiter strap in low position decreases ski pressure...
  • Page 53 THE PERFECT FIT Rear Suspension Adjustments Shock Compression Valving The rear track shocks for this model are gas charged shocks. The valv- ing on the gas charged shocks is pre-set.

  • Page 54: Handlebar Adjustments

    THE PERFECT FIT Handlebar Adjustments Use the following steps to adjust handlebar angle at the handlebar block. 1. Remove the mountain bar. 2. Remove the handlebar cover. Mountain 3. Using a 7/16" wrench, loosen the four nuts on the bottom of the adjuster block.
  • Page 55 THE PERFECT FIT 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: •...

  • Page 56: 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. Item See Page Drive Belt Condition Steering System Brake Fluid Brake Lever/Parking Brake Lock 57, 58 Brake System Throttle Lever...

  • Page 57: 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 58: Hood Latches

    PRE-RIDE INSPECTIONS Before Starting the Engine Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed.

  • Page 59: Brake Lever Travel

    PRE-RIDE INSPECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the 1/2" (1.3 cm) handgrip than 1/2" (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.

  • Page 60: Parking Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock Brake Parking Brake only when you want the snowmo- Lever Lever Lock bile to remain stationary; for exam- ple, when parked on an incline for a period of five minutes or less.

  • Page 61: Track Inspection

    PRE-RIDE INSPECTIONS Before Starting the Engine Track Inspection WARNING! Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle. WARNING! Use of traction products such as studs increases the possibility of track damage and/or failure.

  • Page 62: Suspension Inspection

    PRE-RIDE INSPECTIONS Before Starting the Engine 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. Item Check Page...

  • Page 63: Engine Stop Switch

    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. Lighting Check the headlight (high and low beam), taillight, and brake light.

  • Page 64: 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 65: Fuel Recommendation

    OPERATION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher. 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. Never use E85 in your snowmobile).

  • Page 66: Break-In Period

    OPERATION Break-In Period Engine Break-In Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine. Premix the first tank of fuel as outlined below. Oil added to the fuel and oil injection systems will provide the necessary engine lubrication.

  • Page 67: Oil Injection System

    OPERATION Break-In Period Engine Break-In Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Vary the throttle openings and vehicle speeds to reduce friction on all close-fit- ting machined parts, allowing them to break in slowly without damage.

  • Page 68: Starting The Engine

    OPERATION Starting the Engine 1. Turn the key to the ON position. NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 2.

  • Page 69: Stopping The Snowmobile

    OPERATION Restarting an Engine If the rider stops the engine by pushing the engine stop switch down, restart the engine using the normal starting procedure. If the engine fails to start using the normal procedure: 1. Push the engine stop switch down to the OFF position. 2.

  • Page 70: Low Oil Indicator Light

    OPERATION Low Oil Indicator Light The low oil indicator light may flicker at times due to oil movement in the bottle, but when the light comes on and remains on, add the recom- mended oil before further operation. Visually check the oil level in the bottle. The engine may be operated as long as oil is visible in the oil tank.

  • Page 71: Track Warm-Up

    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 72 OPERATION Engine Stop Switch 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 RUN 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 73: Throttle Lever

    OPERATION Throttle Lever WARNING! An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. If the engine speed limits at 2400 RPM when the throttle lever is released: 1.
  • Page 74 OPERATION Electronic Reverse (PERC WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the gearcase or trans- mission if shifting is attempted when the engine is operating above idle speed. •...

  • Page 75: Daily Storage

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

  • Page 76: 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 control information (ECI) label and a factory-installed emissions information hangtag.
  • Page 77 MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log beginning on page 131. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1000 miles (1600 km).
  • Page 78 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine POLARIS parts, available from your POLARIS dealer. Item Frequency Page...
  • Page 79 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 57, 89 Brake Fluid FUEL MANAGEMENT...
  • Page 80 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 Drive Shaft Bearing Skags (Wear Bars) Ski Saddle/Spindle Bolts Hood Straps...

  • Page 81: Gearcase Oil Level

    MAINTENANCE Lubrication Gearcase Oil Level Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 75. Change the gearcase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. To check the oil level, place the snowmobile on a level surface.

  • Page 82: Throttle Cable

    MAINTENANCE Lubrication Throttle Cable Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the han- dlebars to the left and lubri- cate liberally as shown. Front Suspension The front suspension and steering components do not require lubrica- tion.

  • Page 83: Rear Suspension

    MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 76 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km). Lack of lubrication will adversely affect your ride and the life of the sus- pension.

  • Page 84: 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. NOTICE: Using non-recommended spark plugs can result in serious engine damage.
  • Page 85 MAINTENANCE Spark Plugs Normal Spark Plug 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 86: Intake Filters

    MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow. NOTICE: Operating the snowmobile with the intake filters removed may cause intake icing.

  • Page 87: Oil Filter

    MAINTENANCE Oil Lines Inspect oil line condition every 1000 miles (1600 km). Oil Filter The oil filter is located at the side of the oil tank. Have your dealer change the oil filter and bleed the system annually or every 1000 miles (1600 km). Have your dealer inspect the return check valve as well.

  • Page 88: Cooling System

    MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing. Contact your dealer if greater protection is required. Use POLARIS Antifreeze 60/40 Premix. POLARIS Antifreeze is already premixed and ready to use.

  • Page 89: Flushing The Cooling System

    MAINTENANCE Cooling System Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine cool- ant temperature becomes too hot for safe continued operation of the engine. If you must drive your machine after the high temperature indi- cator light has come on, drive slowly and stop frequently to allow the engine to cool down.

  • Page 90: Bleeding The Cooling System

    MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly.

  • Page 91: Brake Components

    MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 57. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate, approximately 1/16" (1.5 mm). A kit is avail- able for replacing brake pads.

  • Page 92: Brake Fluid

    MAINTENANCE Brakes Brake Fluid WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or serious injury.

  • Page 93: 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 94: Removing Halogen Bulbs

    MAINTENANCE Lights Removing Halogen Bulbs Tip: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a resi- due, 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. 1.

  • Page 95: Installing Halogen Bulbs

    MAINTENANCE Lights Installing Halogen Bulbs 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 96: Electrical System

    MAINTENANCE Electrical System RELAY LABEL FUSE LABEL ITEM POWERED START SOLENOID Ground side of start solenoid RELAY SPARE 20A None ACCESSORY Accessory plugs EMERGENCY SPARE 30A CHASSIS High beams RELAY Low beams Handwarmers CHASSIS Thumbwarmer Passenger handwarmers Work light Tail lamp Brake lamp Alternator coils Exhaust sensor...

  • Page 97: Clutch System

    MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. WARNING! If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the snowmobile until repairs have been made.

  • Page 98: Drive Belt Condition

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

  • Page 99: Drive Belt Adjustment

    MAINTENANCE Clutch System Drive Belt Adjustment 1. Install the L-wrench into the open threaded hole in the outer sheave of the clutch (see page 98). Turn the wrench clockwise slightly to remove pressure from the sheaves. 2. Loosen the 7/16-inch jam nut. 3.

  • Page 100: Drive Belt Removal

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

  • Page 101: 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 circumference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the break-in period.

  • Page 102: Track Replacement

    MAINTENANCE Track Replacement When replacing the track, always install a track having the lug size rec- ommended for your model. See your POLARIS dealer. NOTICE: Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel. Always install a track having the lug size recommended for your model.

  • Page 103: Track Lubrication

    MAINTENANCE Track Lubrication WARNING! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication.

  • Page 104: Track Tension

    MAINTENANCE Track Tension WARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track adjustment is critical for proper handling. Always maintain cor- rect tension and alignment.
  • Page 105 MAINTENANCE Track Tension 4. Check for specified slack between the wear surface of the track clip and the plastic rail slide. Idler Shaft Adjusting Bolt Lock Screw If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7.

  • Page 106: Track Alignment

    MAINTENANCE Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the snowmobile with the track off the ground.

  • Page 107: Steering System

    MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride. Tighten any loose fasteners.

  • Page 108: Ski Alignment

    MAINTENANCE Steering System Ski Alignment WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your POLARIS dealer. 1. Place the handlebars in a straight-ahead position. 2.

  • Page 109: Ski Skags

    MAINTENANCE 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 110: Battery Removal

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

  • Page 111: Battery Charging

    MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.
  • Page 112 MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 or greater.

  • Page 113: Cleaning And Preservation

    Matte Clear Coat Cleaning (if equipped) Matte finish products are prone to trapping dirt, oils and other contaminants. POLARIS Industries recommends cleaning with warm water and a mild dish detergent. Use a soft sponge to gently rub the surface and rinse with clean warm water. For stubborn stains such as grease or oil use a citrus based cleaner (3M Citrus Base Cleaner recommended).

  • Page 114: Battery Maintenance

    MAINTENANCE Extended Storage Battery Maintenance Remove the battery and recharge it as outlined on page 110. Store the battery in a cool, dry place. Controls and Linkage Lubricate all bushings and cables at the intervals outlined in the Periodic Maintenance Table beginning on page 76. Bearings Grease the jackshaft and drive shaft clutch side bearings with POLARIS All-Season Grease or a similar high quality grease to prevent corrosion.

  • Page 115: Electrical Connections

    MAINTENANCE 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. The snowmobile should be supported off the ground to allow the track to hang freely.

  • Page 116: Specifications

    SPECIFICATIONS Capacities and Dimensions Body Style Rider Capacity Coolant Capacity 9.8 qts. (9.3 l) Fuel Capacity 14.3 gal. (54.1 l) Oil Capacity 3.6 qts. (3.4 l) Gearcase Oil Capacity 20 oz. (591.5 ml) Length 138 in. (351 cm) Width 48.75 in. (124 cm) Height 55 in.
  • Page 117 SPECIFICATIONS Clutching Chart ALTITUDE Drive Clutch Drive Clutch Driven Clutch Driven Chaincase Meters Shift Weight Spring Spring Helix Gearing/ (Feet) Pitch *Shaded cells indicate factory settings. 0-600 11-64 Dark 140/200 P2 Tab 40/38-.45 P2N 19:41 (0-2000) (1322604) Blue/White (7043495) (5137157) Borg/Warner (7041781) 600-1200...

  • Page 118: Polaris Products

    POLARIS PRODUCTS Description Part No. Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2875035 Premium Blue 2-Cycle Oil (qt./.95 l) (break-in only) 2875036 Premium Blue 2-Cycle Oil (gal./3.8 l) (break-in only) 2877882 VES 2-Cycle Oil (qt./.95 l) 2877953 VES 2-Cycle Engine Oil (2 qt./1.9 l) 2877883 VES 2-Cycle Engine Oil (gal./3.8 l) 2877884...

  • Page 119: 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 oper- Drive clutch binding • SEE YOUR DEALER. ating RPM during Driven clutch • SEE YOUR DEALER. acceleration or load malfunction variations...
  • Page 120 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch • SEE YOUR DEALER. system components Bearing failure/ • SEE YOUR DEALER. gearcase, jackshaft, or front drive shaft Drive belt surface • Inspect and replace as needed. flat spots Drive chain loose •...
  • Page 121 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 122: Suspension Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension • Set static sag (see page 48). Adjust torsion spring blocks or bottoms too easily install optional torsion springs to achieve correct sag dimensions. Rides too stiff in rear • Check for binding suspension components and grease all pivot points.

  • Page 123: Drive Belt Wear/Burn

    TROUBLESHOOTING Drive Belt Wear/Burn Cause Solution Driving at low RPM Drive at higher RPM. Gear the machine down. Check belt deflection. Insufficient warm-up Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from the snow.

  • Page 124: Warranty

    WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual.
  • Page 125 WARRANTY Service And Warranty Information POLARIS Anti-Theft System The POLARIS anti-theft system (PATS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. POLARIS snowmobile owner reports theft. A. In addition to notifying the proper law enforcement officials, the owner must call POLARIS Customer Service.

  • Page 126: 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. Warranty period will vary regionally. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty.

  • Page 127: Engine Oil

    WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR- TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR- RANTIES NOT STATED IN THIS WARRANTY.
  • Page 128 WARRANTY Conditions and Exclusions 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 129 Vehicles importa- tion rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS Industries in order to register your vehicle in your new country.
  • Page 130 WARRANTY How to Get Service 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. You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle.
  • Page 131 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 132 WARRANTY U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR- RANTY.

  • Page 133: 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 134 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 135 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 136: Index

    INDEX Accessories ....53 DC Outlet, 12-Volt ....32 Air Pollution .
  • Page 137 INDEX Gauge Cleaning....45 Oil Filter ..... . 85 Gearcase Oil Level .
  • Page 138 INDEX Specifications....114-115 Throttle Cable Lubrication ..80 Speed ......15 Throttle Lever .
  • Page 139 PMS 419 For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polaris.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9924294 Rev 01 Printed in USA *9924294...

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