Polaris 600 IQ Widetrak Owner's Manual
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Polaris 600 IQ Widetrak Owner's Manual

Polaris 600 IQ Widetrak Owner's Manual

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

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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 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. 9923387 Rev 01 Printed in USA *9923387...
  • Page 5 • Victory Motorcycles ® • Low emission vehicles (LEVs) 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 pro-...
  • Page 6 POLARIS, THE WAY OUT and IQ are registered trademarks of POLARIS Industries Inc. Copyright 2011 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 7: Table Of Contents

    POLARIS Products..... 116 Troubleshooting ..... . . 117 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

    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 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 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: 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 16: Eye Protection

    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 17: 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 18: 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 19: 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 observe all state and local laws governing snowmobile opera- tion and speed limits.

  • Page 20: 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 21 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 22: 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 23: 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 24: 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 25: 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 26: 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 27 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 28: Clutch Warning

    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 Warning...

  • Page 29: 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 30: Reverse Warning

    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 31: 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 32: 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. Grab Handle Heater Switch 8. Handlebar 18. Backrest Adjustment Knob 9.

  • Page 33: 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 34: Features

    FEATURES Backrest The backrest is adjustable for either operator or passenger use. 1. Loosen the upper adjustment knobs to raise or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest for- ward for operator use or rear- Raise/Lower ward for passenger use.

  • Page 35: Features

    FEATURES Adjustable Headlights Move the headlight adjuster to raise or lower the headlight beam. • Move the adjuster to the left to lower the beam. • Move the adjuster to the right to raise the beam. Shifter Shifter For normal operation, place the transmission in high gear.

  • Page 36: 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 37: 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 64-65 for fuel information and recommendations. The ECU fuel designation connector must have the “NON-ETHANOL 160 OHM”...

  • Page 38: Features

    Low fuel/no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel filter or tank pick-up sock See your POLARIS dealer for service Alcohol-based fuel additive used with Do not add de-icers or additives that Ethanol fuel...

  • Page 39: 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 40: 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 41: 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 42: 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 43: Features

    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 44: 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 45 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 46: 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 47: 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 48: 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 49: 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 50: Features

    FEATURES Instrumentation MFD Battery Replacement Models equipped with the clock feature have a battery to power the clock. If the clock function of the MFD isn't working properly, replace the battery. Replace- ment batteries are available from your dealer. 1. Remove the plenum from the under- side of the hood.

  • Page 51: Features

    FEATURES Instrumentation MFD Battery Replacement 5. Using needle-nose pliers, grasp the battery and rotate it so the lead- ing edge of the battery is raised away from the battery holder. Pull the battery out gently. Tip: The battery will not come out of the holder unless the leading edge of the battery is raised.

  • Page 52: The Perfect Fit

    • Camber (see your dealer) Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your POLARIS dealer for assistance before attempting to adjust preload. Increasing the spring preload too much may adversely affect the han- dling of the snowmobile and the performance of the rear suspension.

  • Page 53: Suspension Performance Tips

    • In deep snow, a new rail slide will offer improved performance over a worn slide. It can also improve top speed. • 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 54: 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 55: 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 56 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 57 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 58: 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 59 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 snowmo- bile. Use of unapproved parts and accessories may result in: •...

  • Page 60: 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 61: 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 62: Hood Latches

    PRE-RIDE INSPECTIONS Before Starting the Engine n 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 63: Brake Lever Travel

    PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the 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 64: Parking Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine n 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 65: Track Inspection

    PRE-RIDE INSPECTIONS Before Starting the Engine n 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 66: Suspension Inspection

    PRE-RIDE INSPECTIONS Before Starting the Engine n 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.

  • Page 67: Start The Engine And Check

    PRE-RIDE INSPECTIONS Start the Engine and Check Engine Stop Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF. Lighting Check the headlight (high and low beam), taillight, and brake light.

  • Page 68: 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 69: Fuel Recommendation

    Never use deicers or additives containing methanol. POLARIS also recommends the use of Carbon Clean Plus. See page 116 for the part numbers of POLARIS products. If you use fuel with up to 10% ethanol (sometimes labeled “oxygen-...

  • Page 70: Break-In Period

    Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. 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. Initial Fuel Premix Always premix fuel in 5-gallon (19-liter) increments in a separate fuel container.

  • Page 71: Oil Injection System

    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 72: 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 73: 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 74: Low Oil Indicator Light

    Always check the oil level when refu- eling. Add oil as needed. The POLARIS oil cap on the oil bottle is vented to allow proper oil flow. See your POLARIS dealer for recommended replacement parts.

  • Page 75: 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 76 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 77: Throttle Lever

    The lever and cable must return to the idle position quickly and completely. 4. If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures. 5. If the engine doesn't start, take the snowmobile to an authorized POLARIS dealer for service.
  • Page 78 OPERATION Electronic Reverse (PERCt) 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 79: 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 80: 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 81 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 snowmobile on its side for service or inspection.

  • Page 82: Item See Page

    The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine POLARIS parts, available from your POLARIS dealer. Item Frequency Page 150 mi.

  • Page 83: Throttle Safety Switch

    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 59, 91 Brake Fluid FUEL MANAGEMENT...

  • Page 84: Gearcase Oil Level

    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 85: Gearcase Oil Level

    POLARIS recommends the use of POLARIS Synthetic Chaincase Lube. See page 116 for the part numbers of POLARIS products. NOTICE: Mixing brands or using non-recommended lubricants could result in excessive wear to chain, sprockets and bearings. Always use...

  • Page 86: 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 87: Rear Suspension

    MAINTENANCE Lubrication 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 78 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

  • Page 88: 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 89 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 90: Intake Filters

    Do not attempt to service the fuel pump. Fuel Filter/Fuel Lines See your POLARIS dealer for replacement of the fuel filter at the inter- vals outlined in the Periodic Maintenance Table beginning on page 78. Contaminated or poor quality fuel will shorten the life of the fuel filter and result in poor engine performance.

  • Page 91: Oil Filter

    4. Replace any damaged or missing components. 5. Clean the plastic surfaces next to the muffler with aerosol Carbure- tor and Throttle Body Cleaner. See page 116 for the part numbers of POLARIS products. 6. Close the hood.

  • Page 92: Cooling System

    Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/ 40% water mixture. See page 116 for the part numbers of POLARIS products. Tip: Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.

  • Page 93: Flushing The Cooling System

    To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh mix- ture of antifreeze and distilled water should be added. Have your POLARIS dealer perform this service.

  • Page 94: 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 95: Brake Components

    MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 59. 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 96: Brake Fluid

    1. Position the handlebars so the master cylinder is level. 2. Remove the master cylinder cover. 3. Add DOT 4 brake fluid only. Do not overfill. See page 116 for the part numbers of POLARIS products.

  • Page 97: 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 98: 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 99: 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 100: 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 101: 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 lubricate clutch bushings.
  • Page 102 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 103: 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 100). Turn the wrench clockwise slightly to remove pressure from the sheaves. 2. Loosen the 7/16-inch jam nut. 3.

  • Page 104: 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 105: 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 106: Track Replacement

    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 107: 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 108: 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 109 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 110: Track Alignment/Condition

    35 ft. lbs. (47.5 Nm). 5. Repeat steps 2 and 3 to verify proper alignment. Rail Slide Wear For ease of inspection, all POLARIS rail slides have a Minimum wear limit indicator groove to Thickness indicate the minimum permissi- ble slide thickness.

  • Page 111: 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 112: 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. 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 113: Ski Skags

    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 control while turning on hard-packed snow or ice.

  • Page 114: 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 115: Battery Charging

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. Tip: Battery charge can be maintained by using a POLARIS Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge.
  • Page 116 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 117: 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 116 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 118: Battery Maintenance

    Lubricate all bushings and cables at the intervals outlined in the Periodic Maintenance Table beginning on page 78. Bearings Grease the jackshaft and drive shaft clutch side bearings with POLARIS Premium All-Season Grease or a similar high quality grease to prevent corrosion.

  • Page 119: 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 120: Polaris Products

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

  • Page 121: 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 mal- •...
  • Page 122 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 123 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 124: Suspension Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension • Set static sag (see page 50). 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 125: Drive Belt Wear/Burn

    TROUBLESHOOTING Drive Belt Wear/Burn Cause Solution Driving at low Drive at higher RPM. Gear the machine down. Check belt deflection. Insufficient warm- 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 126: 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 127 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 128: Limited Warranty

    POLARIS’ control. This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the snowmobile.

  • Page 129: Engine Oil

    • Two-year extended engine coverage • Two-year powertrain coverage • Extended service contract If you selected any type of extended warranty coverage as part of a POLARIS retail pro- gram, please contact any authorized POLARIS dealer for additional information. How to Obtain Warranty Service If your snowmobile requires warranty service, you must take it to a POLARIS dealer authorized to repair POLARIS snowmobiles.
  • Page 130 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 131 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...
  • Page 132 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 133 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 134 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 135: 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 136 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 137 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 138: Index

    INDEX Accessories ....55 DC Outlet, 12-Volt ....32 Air Pollution .
  • Page 139 Passenger Warning ....25 Polaris Products ....116 Pre-Ride Checklist ....56 Ice and Snow Build-up .
  • Page 140 INDEX Spring Preload, IQ ....50 Throttle Cable Lubrication ..82 Starting the Engine ... . . 68 Throttle Lever .

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