Polaris 600 Dragon SP Manuals

Manuals and User Guides for Polaris 600 Dragon SP. We have 5 Polaris 600 Dragon SP manuals available for free PDF download: Service Manual, Owner's Manual

Polaris 600 Dragon SP Service Manual (308 pages)

Brand: Polaris | Category: Motorcycle | Size: 30.55 MB

General Information

5
- Table of Contents
  5
- Model Identification
  6
- Serial Number Location
  6
- Sportsman Models Identification
  7
  - U 1/2
    10
- Publication Numbers
  14
- Paint Codes
  14
- Replacement Keys
  14
- Standard Torque Specifications
  15
- Conversion Table
  16
- Glossary of Terms
  18
Maintenance

19
- Periodic Maintenance Chart
  20
- Pre-Ride Inspection
  22
- Special Tools
  24
- Front & Rear Gearcase Lubrication
  27
- Transmission Lubrication
  29
  - Throttle Inspection
    31
  - Idle Speed Adjustment
    32
  - Throttle Cable
    32
- Fuel System
  33
- Compression Test
  34
  - Fuel Filter
    34
  - Carburetor Draining
    34
- Battery Maintenance
  35
- Ignition Timing
  36
  - Spark Plug
    36
- Radiator Screen Removal
  38
  - Coolant Level Inspection
    38
- Air Box Sediment Tube Service
  39
- Breather Filter
  40
- PVT Drying & PVT Drain Plug
  40
- Oil Change/Filter
  41
  - Engine Oil Level
    41
  - Wheel Alignment
    44
  - Brake Pad Inspection
    46
  - Front Suspension
    47
  - Rear Suspension
    47
- Controls
  48
- Tire Inspection
  48
- Wheel Removal/Installation
  48
  - Wheel Installation
    48
  - Tire Pressure
    48
  - Torque Table
    48
- Warn Winch Operation
  49
Table of Contents

51
- Engine Exploded Views
  52
  - Top End
    55
- Piston Identification
  57
- Special Tools
  57
- Torque Specifications
  58
- Engine Fastener Torque Patterns
  59
- 600 Engine Service Data
  60
- Cooling System Specifications
  64
- Cooling System Test
  64
- Engine Installation Notes
  66
- Oil Flow
  68
- Rocker Arm/Pushrod Inspection
  69
  - Cylinder Head Removal
    69
- Cylinder Head Disassembly/Inspection
  70
  - Cylinder Head Inspection
    70
- Valve Inspection
  72
- Combustion Chamber
  73
- Valve Seat Reconditioning
  73
- Cylinder Head Assembly
  75
- Valve Sealing Test
  76
- Valve Train Exploded View
  76
- Engine Head Reassembly
  77
- Cylinder Removal
  79
- Piston Removal
  79
- Valve Lifter Removal/Inspection
  79
- Cylinder Inspection
  80
  - Piston Ring Installed Gap
    83
- Starter Bendix Removal/Inspection
  84
- Flywheel/Stator Installation
  85
- Flywheel/Stator Removal/Inspection
  85
- Engine Crankcase Disassembly/Inspection
  86
- Camshaft Inspection
  94
- Engine Crankcase Assembly
  95
- Troubleshooting
  106
Fuel System/Carburetion

109
- Fuel Flow Diagram
  111
- Carburetor Jetting
  112
- Assembly, CV Carburetor
  113
  - Float System
    115
  - Main System
    115
  - Carburetor Inspection
    117
  - Carburetor Cleaning
    117
  - Carburetor Assembly
    118
- CV Carburetor System Function (4 Cycle)
  113
- Needle & Seat Leakage Test
  119
- Fuel Level
  120
- Fuel Pump Service
  120
  - Fuel Pump Disassembly
    120
- Fuel Sender Service
  121
- Troubleshooting
  121
Table of Contents

123
- Cover/Panel Removal
  124
- Side Panel Removal
  125
- Body Assembly Exploded View
  127
- Body Rack Assembly, Exploded View
  128
- Headlight Pod Exploded View
  130
- Steering/A--Arm Exploded View
  131
- Rear Suspension Exploded View
  132
- A-Arm Replacement
  133
- Steering Post Assembly
  134
- Front Strut Assembly Exploded View
  135
- Front Strut Cartridge Replacement
  136
- Decal Replacement
  137
Clutch

139
- Drive Clutch Exploded View
  140
- PVT Sealing and Ducting Components
  140
- PVT Operation Overview
  142
- PVT Overheating/Diagnosis
  144
- PVT Disassembly
  145
- PVT Assembly/Inspection
  146
- Drive Clutch Spring Specifications
  147
- Shift Weights /Inspection
  148
- Drive Clutch Disassembly/Inspection
  149
  - Clearance Inspection
    149
- Drive Clutch Reassembly
  151
- Drive Belt Removal/Inspection
  152
- Clutch Alignment/Offset
  154
- Drive Belt Installation
  154
- Late 2004 Driven Clutch Inspection
  166
- Troubleshooting
  171
Table of Contents

173
- Final Drive
  174
- Front Drive Axle Removal
  175
- Front Hub Inspection
  175
- Driveshaft & CV Joint Handling Tips
  176
- Front Drive Axle Installation
  176
- Front Hub Disassembly & Assembly
  178
- U--Joint Assembly
  179
- U-Joint Disassembly
  179
- Front Gearcase Removal/Install
  180
- Early 2004 Front Gearcase Exploded View
  188
- Late 2004 Front Gearcase Information
  189
- Rear Hub Removal
  198
- Rear Hub Installation
  199
- Rear Hub Assembly
  200
- Rear Hub Disassembly
  200
- Rear Driveshaft Removal
  201
- Driveshaft and CV Joint Tips
  202
- Rear Driveshaft Installation
  202
- Rear Driveshaft Service
  203
- Rear Gearcase Removal
  205
- Rear Gearcase Assembly
  206
- Rear Gearcase Disassembly
  206
- Rear Gearcase Installation
  206
- Rear Gearcase Exploded View
  209
Transmission

211
- Transmission, Exploded View
  212
- Gear Shift Selector Removal
  216
- Torque Specifications/Lubrication
  216
- Transmission Removal
  216
- Transmission Installation
  217
- Transmission Disassembly
  218
- Transmission Reassembly
  223
Brakes

229
- 2004 Brake Line Identification
  231
- Brake Noise Troubleshooting
  231
- Brake System Service Notes
  231
- Hydraulic Brake System Overview
  232
- Brake Bleeding / Fluid Change
  233
- Hydraulic Caliper Bleeding
  233
- Master Cylinder Installation
  235
- Master Cylinder Removal
  235
- Front Pad Removal
  236
- Front Pad Installation
  237
- Brake Burnishing
  238
- Front Disc Inspection
  238
- Front Disc Removal/Replacement
  238
- Front Caliper Disassembly
  239
- Front Caliper Removal
  239
- Front Caliper Inspection
  240
- Front Caliper Installation
  241
- Front Caliper Reassembly
  241
- Front Caliper Exploded View
  243
- Rear Pad Removal
  244
- Rear Pad Installation
  245
- Rear Caliper Reassembly
  246
  - Rear Caliper Assembly
    247
- Rear Caliper Removal/Inspection
  246
- Rear Disc Inspection
  248
- Rear Caliper Exploded View
  250
- Troubleshooting
  250
Table of Contents

251
- Timing Check Procedure
  252
- Gear Position Switch Test
  254
- Instrument Cluster Overview
  254
  - Diagnostic Mode
    256
- Speedometer Removal/Installation
  258
- Speedometer Operation Troubleshooting
  260
- Fan Control Switch Tests
  265
  - Coolant Temperature
    265
- Fan Motor Tests
  265
- Flywheel Identification
  267
- Ignition System Testing Flow Chart
  269
- Ignition System Troubleshooting
  270
- Battery Identification
  273
  - Conventional Battery Installation
    274
  - Conventional Battery Testing
    274
  - Battery Check
    276
  - Battery Charging
    277
  - Battery Inspection
    278
  - Battery Testing
    278
  - Battery Installation
    278
  - Bulb Replacement
    280
  - Headlamp Switch
    282
- Fuel Sender Service
  283
- Hand / Thumb Warmer Switches
  283
- Starter System Troubleshooting
  286
  - Starter Motor Removal
    286
- Starter Drive
  290
- Starter System Testing Flow Chart
  292

Polaris 600 Dragon SP Owner's Manual (141 pages)

Polaris 2009 Snowmobile Owner's Manual

Brand: Polaris | Category: Snowmobiles | Size: 7.5 MB

Table of Contents

6
- Introduction
  8
- Safety
  11
  - Operator Safety
    12
  - Riding Position
    13
  - Riding Apparel
    14
    
    Disabled Operators
    15
    
    Survival Preparation
    15
  - Rider Capacity
    16
  - Driver Awareness
    17
  - Ice and Snow Build-Up
    19
    
    Driving on Slippery Surfaces
    19
    
    Driving Downhill
    20
    
    Driving in Hilly Terrain
    21
    
    Drive Belt
    22
  - Intake Silencer
    22
  - Cold Weather Drive-Away
    22
  - Inadequate Snow Conditions
    23
  - Operating in Deep Snow
    23
    
    Driving Responsibly
    24
    
    Clutch Cover Warning
    26
  - Pressure Cap Warning
    26
  - Hot Surface Warning
    27
    
    Track Warning
    27
    
    Safety Decals and Locations
    28
  - Reverse Warning
    28
  - Operation Warning
    28
- Features
  30
- Features
  32
  - Cargo Area
    32
  - Adjustable Headlights
    32
  - Features
    33
  - Features
    34
  - Mfd Settings
    34
    
    Features
    35
    
    Features
    36
    
    Features
    37
    
    Features
    38
    
    Features
    39
    
    Features
    40
    
    Features
    41
    
    Features
    42
    
    Features
    43
  - Gauge Cleaning
    43
- The Perfect Fit
  44
  - Front Suspension Adjustments
    45
  - Shock Spring Preload
    45
  - Shock Valving
    46
  - Rear Suspension Adjustments
    47
    
    Suspension Performance Tips
    48
    
    Torsion Spring Preload
    51
    
    Suspension Coupling
    54
    
    Weight Transfer During Acceleration
    56
  - Handlebar Position
    57
  - Handlebar Adjustments
    57
  - Handlebar Angle
    57
    
    Traction Products
    59
    
    Wear Strips
    60
Pre-Ride Inspections Pre-Ride Checklist

61
- Pre-Ride Inspections
  61
  - Before Starting the Engine
    62
  - Brake Lever Travel
    63
  - Parking Brake Lever Lock
    64
  - Steering System
    65
  - Hood Latches
    66
    
    Recoil Rope
    66
    
    Start the Engine and Check
    67
- Operation
  68
  - Starting the Engine
    68
  - Engine Break-In
    69
  - Oil Injection System
    70
  - Oil Recommendations
    70
    
    Slide Rail and Track Cooling
    70
    
    Track Warm-Up
    71
    
    Fuel System Deicers
    73
  - Low Oil Indicator Light
    74
    
    Engine Stop Switch
    75
    
    Throttle Lever
    76
    
    Emergency Stopping
    77
    
    Daily Storage
    80
- Maintenance
  81
- Coolant Level
  83
- Drive Belt Condition
  83
- Item See Page
  83
- Recoil Rope
  83
- Ignition Switch
  84
- Taillight/Brakelight/Headlight
  84
- Hood Straps/Latches
  85
- Rear Wheel Idler Bolts
  85
  - Rear Suspension
    86
  - Throttle Cable
    87
  - Driveshaft Bearing
    87
  - Chaincase Oil
    88
  - Spark Plugs
    90
  - Spark Plug Condition
    91
  - Oil Filter
    92
  - Oil Lines
    92
  - Intake Filters
    93
    
    Fuel Pump
    93
    
    Cooling System
    94
    
    Flushing the Cooling System
    95
    
    Bleeding the Cooling System
    96
    
    Exhaust System
    97
    
    Drive Chain Tension
    98
    
    Brake Components
    99
    
    Brake Fluid
    100
    
    Bleeding the Hydraulic Brake System
    101
  - Headlight Bulb Removal
    102
  - Headlight Bulb Installation
    102
    
    Clutch System
    104
    
    Clutch Alignment Offset
    104
    
    Clutch Center Distance
    104
    
    Drive Belt Deflection
    106
    
    Drive Belt Adjustment
    106
    
    Drive Belt Removal
    107
    
    Drive Belt Installation
    108
    
    Torque Stop
    108
    
    Track Inspection
    109
    
    Track Lubrication
    110
    
    Track Tension
    111
- Skags (Wear Bars)
  85
- Ski Saddle and Spindle Bolts
  85
- Suspension Mounting Bolts
  85
- Track Alignment/Condition
  113
  - Ski Alignment
    115
  - Ski Skags
    116
  - Rail Slide Wear
    117
  - Suspension Maintenance
    117
  - Pre-Ride Suspension Inspection
    117
    
    Cleaning and Preservation
    118
    
    Controls and Linkage
    118
    
    Clutch and Drive System
    119
    
    Engine Protection
    119
    
    Electrical Connections
    120
    
    Transporting the Snowmobile
    120
- Polaris Products
  121
- Troubleshooting
  122
  - Drive Belt Troubleshooting
    126
- Warranty
  127
  - Limited Warranty
    129
  - Engine Oil
    130
- Maintenance Log
  136
- Index
  139

Polaris 600 Dragon SP Owner's Manual (153 pages)

Polaris 2003 ATV Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 2.68 MB

Welcome
5
Table of Contents
7
Vehicle Identification Numbers
8
- Age Restrictions
  9
- Operator Safety
  10
Safety
9
- Equipment Modifications
  13
- Safety Decals and Locations
  34
- Safe Riding Gear
  38
- Electrical Switches
  39
- Throttle Lever
  40
Controls
39
- Light Switches
  41
- Brake Lever
  42
- Parking Brake
  43
  - Auxiliary Brake
    44
  - Fuel Filter
    45
  - Fuel Tank
    45
  - Fuel Valve
    45
  - Fuel Safety
    46
  - Belt Life
    48
- Recoil Starter
  49
Engaging Wheel Hubs
50
Features
50
- Disengaging Wheel Hubs
  51
- Indicator Lights
  52
- Instrument Cluster
  53
- Rider Information Center
  54
  - Diagnostic Mode
    57
  - Break-In Period
    58
- Starting a Cold Engine
  61
- Starting the Engine
  61
- Starting a Warm Engine
  62
Operation
58
- Hauling Cargo
  63
- Driving Procedures
  65
- Driving Safely
  65
- Making Turns
  66
- Driving on Slippery Surfaces
  67
- Driving Uphill
  68
- Driving Downhill
  70
- Turning Around on a Hill
  71
  - Driving through Water
    72
  - Driving over Obstacles
    73
  - Driving in Reverse
    74
- Parking on an Incline
  75
Noise Emission Control System Regulation
76
- Usfs Approved Spark Arrestor
  76
Maintenance and Lubrication
77
- Periodic Maintenance Schedule
  78
- Lubrication Recommendations
  82
- Premium 2-Cycle Oil
  87
- Premium Gold Synthetic 2-Cycle Oil
  87
- Premium 4 Synthetic Oil
  88
- Transmission Oil Change - Sportsman
  96
  - Front Gearcase Oil Change
    97
  - Front Gearcase Oil Check
    97
- Rear Gearcase Oil Change
  98
- Rear Gearcase Oil Check
  98
  - Engine Oil Check
    100
  - Coolant Level
    101
  - Engine Cooling System
    101
- Radiator Coolant Level
  102
- Oil Pump Bleeding - 2-Cycle Engines
  103
- Front Brake
  106
- Rear Brake
  107
- Toe Alignment
  108
- Camber and Caster
  109
- Rear Spring
  109
- Steering Assembly
  109
  - Adjusting Carburetor/2-Cycle Engines
    111
  - Adjustments
    111
- Throttle Cable Freeplay
  112
- Side Panel Removal - Gen IV
  113
- Wheel Removal
  114
- Wheel Installation
  115
- Wheel Nut Torque Specifications
  115
- Front Wheel Hub Tightening
  116
- Tire Tread Depth
  116
  - Drive Chain
    117
  - Filter Systems
    120
  - Headlight Lamp Replacement - Scrambler
    122
  - High Beam Adjustment - Scrambler
    122
  - Headlight Adjustment - Trail Blazer
    123
  - Headlight Lamp Replacement - Trail Blazer
    123
  - Headlight Lamp Replacement - Gen IV
    124
  - High Beam Adjustment - Gen IV
    125
  - Headlight Housing Replacement - Gen IV
    126
  - Indicator Lamp Replacement
    127
- Taillight/Brakelight Lamp Replacement
  127
- Spark Plug Removal and Replacement
  128
- Spark Plugs
  128
- Vehicle Immersion
  129
- Spark Arrestor
  130
- Recoil Housing
  132
  - High Range
    133
  - Low Range
    133
- Pvt System
  133
- Pvt Drying
  134
  - Battery (Conventional)
    135
  - Battery Removal
    136
  - Battery Installation
    137
  - Battery Storage
    137
  - Cleaning and Storage
    139
  - Cleaning the Atv
    139
- Washing the Atv
  139
- Waxing the Atv
  139
- Fluid Levels
  140
- Storage Tips
  141
- Transporting the Atv
  142
Polaris Recommended Products
143
Troubleshooting
144
Warranty
148
Engine Oil
150
Index
151

Polaris 600 Dragon SP Owner's Manual (129 pages)

Vehicle Maintenance and Safety

Brand: Polaris | Category: Offroad Vehicle | Size: 2.41 MB

Welcome
5
Vehicle Identification Numbers
6
Table of Contents
7
Safety
8
- Safe Riding Gear
  12
- Operator Safety
  13
- Age Restrictions
  13
- Safety Training
  13
- Equipment Modifications
  17
Controls
38
- Throttle Lever
  39
- Light Switches
  40
- Brake Lever
  40
- Master Cylinder
  41
- Parking Brake
  42
Setting the Parking Brake
42
- Brake Fluid Level
  43
- Fuel Filter
  44
- Fuel Tank
  44
- Fuel Valve
  44
Features
46
- Engaging Front Gearcase
  46
- Instrument Cluster
  47
- Diagnostic Mode
  51
Operation
52
- Fuel Safety
  52
- Break-In Period
  53
- Pre-Ride Inspection
  54
- Starting the Engine
  55
- Starting a Cold Engine
  55
- Starting a Warm Engine
  56
- Cold Weather Operation
  56
- Hauling Cargo
  57
- Driving Safely
  59
- Driving Procedures
  59
- Making Turns
  60
- Driving on Slippery Surfaces
  61
- Traveling Uphill
  62
- Traveling Downhill
  64
- Turning Around on a Hill
  65
- Driving through Water
  66
- Driving over Obstacles
  67
- Driving in Reverse
  68
- Parking on an Incline
  69
Noise Emission Control System Regulation
70
- Usfs Approved Spark Arrestor
  70
Maintenance and Lubrication
71
- Periodic Maintenance Schedule
  72
- Lubrication Recommendations
  78
- Premium 4 Synthetic Lubricant
  80
- Engine Oil Check
  81
- Transmission Oil Change
  83
- Transmission Oil Check
  83
- Front Gearcase Oil Change
  84
- Front Gearcase Oil Check
  84
- Rear Gearcase Oil Change
  85
- Rear Gearcase Oil Check
  85
- Coolant Level
  86
- Engine Cooling System
  86
- Radiator Coolant Level
  87
  - Front Brake
    88
  - Rear Brake
    89
- Toe Alignment
  90
- Camber and Caster
  91
- Rear Spring
  91
- Steering Assembly
  91
- Carburetor/Idle Rpm
  93
- Throttle Cable Freeplay
  94
Side Panel Removal
95
- Wheel Removal
  96
- Front Wheel Hub Tightening
  97
- Wheel Installation
  97
- Wheel Nut Torque Specifications
  97
- Air Filter Service
  98
- Filter Systems
  98
- Headlight Lamp Replacement
  99
- High Beam Adjustment
  100
- Spark Plugs
  103
- Vehicle Immersion
  104
- Spark Arrestor
  105
- High Range
  106
- Low Range
  106
- Pvt System
  106
- Pvt Drying
  107
- Battery Removal
  109
- Battery Storage
  110
- Battery Maintenance
  114
- Transporting the Atv
  114
Troubleshooting
115
Engine Overheating
118
Polaris-Recommended Products
119
Specifications
120
Warranty
124

Polaris 600 Dragon SP Service Manual (22 pages)

ATV

Brand: Polaris | Category: Offroad Vehicle | Size: 38.71 MB

Table of Contents
5
Model Identification
6
Serial Number Location
6
Machine Dimensions
8
Chapter 1

11
Chapter 2

11
Chapter 3

11
Chapter 4

11
Chapter 5

11
Chapter 6

11
Final Drive

11
- Publication Numbers
  16
- Paint Codes
  16
- Replacement Keys
  16
- Standard Torque Specifications
  17
- Decimal Equivalents
  18
- Decimal Equivalent Chart
  20
- Sae Tap Drill Sizes
  20
- Glossary of Terms
  21

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