Polaris 600 RMK manual

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W ARNING W ARNING Read, understand, and follow al l of the instructions and safety precautions in thi s manual and on all product labels. Failure to follow t he safety precautions could result in serious inj ury or death. The engine exhaust from this product contains chemical s known to cause cancer , birth defects or other reproductive harm. PROPO[...]

1 WELC OME Thank you for purcha sing a Polar is vehicle , and welcome to our world-w ide family of Polaris owne rs. W e proudly produce a n exciting line of utility a nd re cr ea tional produc ts. S Snowmobiles S All-te rr ain ve hicles ( A TVs) S RANGER utility vehicle s S V ict ory m ot orcy cles W e belie ve Polaris sets a standa rd of exc elle [...]

2 PO L AR IS an d PO L AR IS T HE W A Y O UT are registered t radem ark s of Pol aris Indus t ri e s Inc . RIDER SELECT is a tr a dema r k of Pola r is I ndust r ie s I nc. Copyri ght 2005 Pola r is Sa l es I nc . Al l inf or ma ti on c onta i ned wi t hin t hi s publ i ca t ion i s bas e d on the l at e st pr oduc t inf or ma ti on at the t i me o[...]

3 TABLE OF CONTENTS Introducti on 5 ............................... This section contains helpf ul informa tion for owne rs and drivers a nd illustrate s the loca tion of impor tant identif ica tion numbers tha t should be rec orde d in the owner’ s manual. Safety 8 ..................................... This sec tion desc ribes sa fe ve hicle ope[...]

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5 INTRODUCTION Impor tant N otes for Ow ners and D ri vers After r eading this manual, store it in the snowmobile for conve nient ref ere nce . It should remain with the snowmobile whe n sold. Some of the illustrations and photos used in this manua l are gene ra l repr ese ntations. Y our model may dif fe r . Follow the maintena nce progr am ou tli[...]

6 INTRODUCTION Pr eser vation of the Envir onm ent Polaris is committe d to supporting a n environme ntal e duca tion campa ign. W e encour age state a nd provincia l governments ac ross the snowbelt to adopt rigor ous safe ty training progr ams that enc ourage protec tion of our e nvironme nt, including wildlife a nd vegeta tion. Snowmobile clubs [...]

7 INTRODUCTION V ehicl e Identificati on Num bers Recor d your snowmobile’ s identific ation number s and ke y number in the s paces pro vi ded. Rem ove t he s pare k ey and st ore i t i n a s afe pl ace. Y our key can be duplica ted only by mating a Polaris ke y blank with one of your existing ke ys, so if both keys ar e lost, the ignition switc[...]

8 SAFE TY Operator S afety The following signa l words and symbols a ppear throughout this manual a nd on your vehic le. Y our sa fety is involve d when the se words and symbols are use d. Become f amilia r with their mea nings befor e rea ding the manual. The safety aler t sy mbol , on your vehicle or in t his manual, alert s you to t he pot entia[...]

9 SAFE TY Operator S afety Follow the re comme nded mainte nanc e progr am outlined be ginning on page 70 of this manua l to ensur e that a ll cr itical c omponents on the snowmobile ar e thoroughly inspec ted by your de aler a t specif ic mi leag e in terv als . W ARNING Driving a s nowmobile requir es your full at t ention. DO NO T drink alcohol [...]

10 SAFE TY Operator S afety Stay Clear of T r ack Y our snowmobile is propelle d by a re volving trac k that must be partia lly exposed for p roper ope ration. W ARNING Serious injur ies may res ult if hands, feet , or clot hing become entangled in t he tr ack. Be alert when riding, and remain pr operly seat ed to st ay c lear of t he tr ack. Never[...]

11 SAFE TY Operator S afety Survival P repar ation For your safety , always ride in a group of other snowmobilers. Alwa ys tell someone where you’re going a nd how long you expe ct to be gone . If it isn’ t possible to ride w ith other s, and you must trave l into remote areas, al ways carry s urvi val eq ui pm ent t hat ’ s appr opri ate t o[...]

12 SAFE TY Operator S afety Dis a bl e d Op e rat o rs Safe ope ration of this rider -active ve hicle re quire s good judgement and physica l skills. Opera tors with c ognitive or physical disa bilities ha ve an incr ea sed risk of loss of control, which c ould re sult in serious injury or death. Rider Capacity Y our Polaris snowmobile is designed [...]

13 SAFE TY Operator S afety Driver A wareness Slow down when trave ling nea r poles, pos ts , or o th er obs t acles . B e es peci all y aler t if you’re snowmobiling afte r dark. Always be on the alert for wir e fenc es. Single strands are e specia lly danger ous, si nce th ere may be a g reat d is tance betwe en posts. Guy wir es on utility pol[...]

14 SAFE TY Operator S afety A valanch es Snowmobilers should alwa ys be pr operly traine d and equippe d bef ore tra veling in mountainous ter rain: S T ake an aval anche cl as s S T ravel wit h exp erienced p eop le S T ravel on de signated tr ails S Make su re each person i s equ ip ped wi th a shovel, probe and a valanche beacon. Y ou don’ t h[...]

15 SAFE TY Operator S afety Ice and S now Buil d - up W ARNING Ice and s now build-up m ay int erfer e with t he st eering of y our machine, res ulting in s erious injur y or deat h. Keep the underhood area f ree of snow and ic e. Befo re dr iving, manually turn the skis to the lef t and right to be sur e ice a nd snow ar e not inter fer ing with f[...]

16 SAFE TY Operator S afety Driving in Hilly T errain W ARNING Climbing a hill or c ross ing the f ace of a slope m ay res ult in los s of balance and mac hine roll-ov er , causing s erious injur y or deat h. Use caut ion and good judgement when driv ing in hilly t errain. Use e xtra cau tion when ope ra ting in hilly terr ain. If climbing a hill i[...]

17 SAFE TY Operator S afety Drive Belt Do not ope r ate t he e ngine wit h the driv e belt r em ove d. Any servic ing that r equire s opera tion without a belt must be pe rfor med by your dea ler . Ope ration of the engine with the belt remove d may result in injur y or dama ge to the e ngine. Intake Silencer Do not oper at e the engine w ith the i[...]

18 SAFE TY Operator S afety Inadequate S now Condi tions W ARNING Do not dr ive for prolonged per iods on black top, grav el, or ice. Doing so could c ause irr evers ible tr ack dam age and lead to serious injur y . Since snow provides the only lubrication for the power slide suspension and, on liquid coole d models, cooling for the engine, adequa [...]

19 SAFE TY Operator S afety Dr ivi ng Res ponsibly Every snowmobile handles dif fere ntly , and eve n the most docile conditions may become danger ous if oper ator s drive impr operly . If you’re ne w to snowmobiling, acqua int yourself with the machine and with wha t it will a nd won’ t do unde r va rious c onditions. Even seasone d driver s s[...]

20 SAFE TY Operator S afety Windchill/T emper ature Charts The following inf ormation is provide d to help you dete rmine w hen temper ature s bec ome dange rous fo r riding. WIND CHILL CHART ( ° F) Wind Speed in MPH Act ual Ther mome ter Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -2 0 -25 -30 -35 -40 -4 5 Equivalent T emperatur e ( ° F)[...]

21 SAFE TY Safety D ecals and Locations W arning decal s have been placed on t he snowmobil e for your prot ect io n. R ead and fo ll ow t he in st ruct io ns o f the decal s and o th er warnin gs on t he s no wmo bi le careful l y . If any of t he d ecals depi ct ed in thi s manual differ from the decal s on your snowmobile, always read and fo ll [...]

+ 22 SAFE TY Safety D ecals and Locations T rack W arning Wa rm i n g Stay clear of t rack. Do not sit on seat back. Entanglem ent wit h the tr ack or a fall from seat back may resul t i n sever e inj ur y or deat h. “No Passenger” W arning Wa rm i n g This vehi cle i s designed f or operat or only . “NO P ASSENGER” +[...]

23 SAFE TY Safety D ecals and Locations Reverse W arning Reverse oper at ion, even at low speeds, may cause loss of control resul ti ng i n seri ous inj ur y or deat h. T o avoid loss of control , always: S Look behind bef ore and whi le backi ng. S A void shar p tur ns. S Shif t t o or from r ever se only when st opped. S Apply t hrot tl e slowl y[...]

24 SAFE TY Safety D ecals and Locations Operation W arning S T o avoid seri ous inj ury or death, read and under stand al l war nings and the Owner’ s Manual befor e operat ion. I f t he manual is miss- ing, cont act a Polari s dealer for a repl acement . S This vehi cle i s capable of high speeds. Buri ed objects or un- even ter r ain can cause [...]

10 4 3 2 1 14 6 12 11 13 15 9 7 5 7 8 25 FEATURES 1. Hood 2. Headli ght 3. Windshi el d 4. Handlebar 5. Side Shiel d 6. Seat 7. Stor age Compart ment 8. T aillig hts 9. Rear Bumper 10. Snow Flap 1 1. Suspension 12. Tr ack 13. Nosepan 14. Front Bumper 15. Ski 1. Fu e l Fille r Ca p 2. Rider Select t 3. Ignit i on Swit ch 4. Handlebar hook 5. Brake L[...]

26 FEATURES RIDE R S E LECT A djustable Steer ing S ystem The RIDER SELEC T adjustable steering system allows you to adjust the handle bar position to fit your style of riding. Choosi ng the Best RID ER S E LEC T t Pos it io n Posit ion Riding Sty le 1 2 3 Relaxed Trail Rid i ng Rider weight is slight ly behind t he cent er of t he snowmobile f or [...]

27 FEATURES RIDE R S E LECT A djustable Steer ing S ystem W ARNING Att empt ing t o adjust the handlebar posit ion while t he snowmobile is mov ing could res ult in los s of cont rol and ser ious injury or death. Always s top t he snowmobile bef ore at t empt ing to adjus t the steerin g system. 1. S top the snowmobile. 2. P ress the rele ase butto[...]

+ + + 28 FEATURES Fuel V alve The fuel valve is locate d under the hood. T urn the fuel valve of f whene ver the snowmobile is stored or parke d. 1. T urn the valve clockwise to turn of f the fuel supply . 2. T urn the valve counte r -c lockwise to turn on the f uel supply . Seat S torage Compar tm ent Lift the seat le ver ( + ) and lift the seat t[...]

29 FEATURES Detonation E lim inati on T echnology (D .E .T .) The DET system preve nts damage to the engine f rom detonation while developing the maximum power of the e ngine safe ly . A detonation sensor monitor s the engine and re sponds to detonation b y automa tica lly reduc ing the engine timing. This ca n result in de cre ase d engine RPM and[...]

30 FEATURES In st ru men t at io n MFD Com ponent Identific ation Item 1 Analog Gauge 2 Digi tal Gauge 3 DET Indi cator 4 Low Oil I ndicat or 5 High T emp Indi cat or 6 Brake I ndicat or 7 Reverse I ndi cator 8 High Beam I ndicat or Digital Display Identification Item 1 RPM or Speed Alt it ude (if equi pped) Servi ce Int erval 2 Elect ri cal System[...]

31 FEATURES In st ru men t at io n MFD Settings W ith the engine running, use the MFD Control Switch (1) to se t the MFD display to your pr efe re nce. The rocke r switch has a MODE button (2) a nd a SET button (3) . Stan dard vs. Met ric The MFD will display eithe r standa rd or metric units of meas urem ent . Wh il e vi ewi ng a screen t hat d is[...]

32 FEATURES In st ru men t at io n MFD Digital Display Program s Press the MODE button t o cycle through the three MFD progr ams: Perf orma nce , Engine and H istory . Ea ch pr ogram w ill rema in in the display until another is sele cted. NOT E: T he analog will always dis play eit her MP H or engine RPM (whichev er set t ing is selec ted) regardl[...]

33 FEATURES In st ru men t at io n MFD Digital Display Program s Performance Progra m Clock S ettin g 1. While in the CLOCK display , press and hold the SET button for five seconds. 2. When the hour starts fla shing press the SET switch once to advance one hour , or pre ss and hold the SET button to advance the hour once ever y 0.2 seconds. 3. P re[...]

34 FEATURES In st ru men t at io n MFD Digital Display Program s Alt it ude (if e quippe d) The ride r ca n calibr ate the a ltimete r for cur rent atmosphe ric conditions. Altimete r accuracy wil l b e +/-30 0 ft. (9 1 m) after adjustme nt. NOT E: Pr ess and hold t he MO DE s witc h for t en sec onds t o swit ch between st andard and m etr ic unit[...]

35 FEATURES In st ru men t at io n MFD Digital Display Program s History Progra m The H istory Pr ogram a utoma tically displays ele ctr ical syste m voltage leve l and fu el leve l. While in the Histor y mode, pre ss the SET button to view maximum vehicle spe ed, maximum engine rpm or the curre nt service inte rval s e t t i n g . The gauge automa[...]

36 FEATURES In st ru men t at io n MFD Digital Display Program s Ser vic e Int er va l Rem inder The gauge logs the number of engine hours betwee n service r eminde rs. When the logged hours reaches t he designate d ser vice inte rva l (set by the user) , the gauge provides a reminde r that ser vice is due. “SE rVCE ” will flash in the odometer[...]

37 FEATURES In st ru men t at io n MFD Battery Replacem ent If the cloc k function of the MFD isn’ t worki ng p roperl y , repl ace th e bat tery . Rep lacem ent bat teri es are av ail abl e from your deale r . 1. Remove the plenum from the underside of the hood. 2. Locate the black batte ry comp artm ent (1). It has a red wire and a brow n wire [...]

38 FEATURES In st ru men t at io n Gauge Cleanin g 1. W ipe the gauge f ac e as neede d using a clean cloth and a mild soap and wat er sol ut io n. W i pe dry w it h clean , s oft cl ot h. 2. Clean the back side of the ga uge using a clean cloth and a mild soap an d water s ol uti on . Do not rem ove th e elect rical co nnect ors or protec tive rub[...]

1 2 4 3 39 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents Independe nt Front S uspens ion (IFS ) Brea k in the suspe nsion for a pproximate ly 150 miles ( 240 km) bef ore making a ny fine- tuning adjustme nts. Settings will vary f rom rider to rider , depending on ride r we ight, vehicle spe ed, riding style, and trail conditions. W e rec omme[...]

40 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents Front S hock S pr ing Pr el oad The fa ctory pr eloa d setting should be a ppropria te for most riders a nd conditions. Please see your Polar is dealer f or assista nce bef ore atte mpting to adjust pre load. Increasi ng t he sp rin g prelo ad to o mu ch may ad versel y affect the handling of t[...]

41 THE PE RFECT FIT Rear Suspension A djustments Rider we ight, riding style, trail conditions, and ve hicle spe ed a ll af fe ct suspension a ction. Each rear sus pen si on can be adj us ted t o su it ri der preferen ce and deliver e xce llent perf ormanc e for a give n set of conditions. However , all suspension designs and adjustments involve a [...]

42 THE PE RFECT FIT Rear Suspension A djustments Rear Suspension In itial Spr ing Preload S etting (Sag Me thod) T o set up the r ear suspension torsion spring preload, measur e the distance betwee n the ground a nd rea r bumper . Thi s is m eas urem ent X. T ake this measur emen t with no rider and wi th t he rear sus pen si on at fu ll exte nsion[...]

43 THE PE RFECT FIT Rear Suspension A djustments Rear T o rsion Spring T ension T o adjust r ear torsion spring te nsion, rotate the thre e-position c am using the engine spark plug tool. Dif fe rent rate tor sion springs are availa ble if a firmer r ide is desired. Contact your dea ler for more inf ormation. The following inf ormation is provide d[...]

L 44 THE PE RFECT FIT Rear Suspension A djustments Rear Shocks Indy Select Rear Sho ck Some snowmobiles are e quipped with the Indy Select re ar shock, which allows f or adjustme nts to the compr ession valving by tur ning the adjustment scr ew loca ted near the ba se of the shock. Locat e th e adj us tm ent screw ( L ) nea r the base of the shock.[...]

L 45 THE PE RFECT FIT Rear Suspension A djustments Rear Shocks AR VIN Ra pid Adj ust S hock The AR VIN Ra pid Adjust shock is ava ilable a s an option on some models. T urn the Rapid Adjust knob ( L ) on the shock re servoir to make ad justments to the compression damping. Po si ti on s are l abel ed on th e sh ock. When ad ju st in g, we recom men[...]

46 THE PE RFECT FIT Handlebar Adjustm ents Handlebar Position Use the RIDER SELECT fea ture to adjust handlebar position. See page 26. Handl ebar A ngle Follow these steps to adjust handleba r angle a t the handlebar block. 1. Remove the handlebar c over (1) to expose the handleba r and the four adjuste r block bolts (2). NOT E: I f necess ary , r [...]

47 THE PE RFECT FIT Accessor ies Pol aris o ff ers a wi de range of accesso ries for your snowmobi le to help make each ri de mo re enj oyab le. Use only Pol aris part s and accesso ries on your Pol aris snowmobi le. Use of unap prov ed part s and acces sori es m ay resul t i n: S Non-c omplianc e with gove rnme nt/industry re quire ments S V oidin[...]

48 THE PE RFECT FIT T raction P roducts (S witchB ack only) Studs Befor e equipping your machine w ith traction produc ts, be aware of the laws in your a rea perta ining to the use of trac tion products. Use only Polaris tr ac tion products on your snowmobile . T rack warranti es are v oid if track damag e or fai lure res ul ts from im pro per or e[...]

49 THE PE RFECT FIT T raction P roducts (S witchB ack only) n Carbide Skags A skag i s a repl aceable bar at tached to t he underside of the ski to assi st in turning the snowmobile and to pre vent ski wea r ca used by c ontac t with roads and other ba re ter rain. Use c arbide ska gs with studded track s to h elp m ain tai n pro per vehi cl e stee[...]

50 PRE -RIDE IN SPECTI ON S Pre - Ride Ch ecklis t Inspec t all ite ms on the c hec klist for pr oper opera tion or c ondition before each use o f th e sn owm obi le. Pro cedures are ou tlined on the referenced pages . Look for a checkm ark ( n ) on the re fere nced pa ges to locate the pre -ride inspe ction items. I t e m S e e P a g e Item S ee P[...]

51 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine W ARNING Worn, damaged, or malf unct ioning component s may c ause serious injury or death. B efor e st art ing the engine, chec k all component s t o be sur e of pr oper operat ion. Read a nd Under stand Y our Ow ner ’ s Manual Read the Owner ’ s Manual c ompletely and r efe r to it oft[...]

52 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Hood Latche s The hood of the snowmobile protects the opera tor from moving parts as well a s aiding in sound emissi on contr ol and other functions. Under no cir cumstances should your snowmobile be opera ted with the hood open or removed. Always ensur e that the hood straps are in good c[...]

53 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Brakes Always ch eck th e following items fo r proper opera tion befor e starting the engine. Brake L ever T ravel Sq ueeze t he brak e lev er . It should move no close r to the ha ndgrip than 1/2 ″ (1. 3 cm). A smaller dista nce indic ates low bra ke fluid level or air in the hydraulic [...]

4 3 1 2 54 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Par k Brake Lever L ock Use the park brake le ver lock only when you want the machine to remai n st ati onary ; for exam pl e, wh en parked o n an in cli ne for a perio d of five minutes or less. 1. B rake Lev er 2. P ark B rake Lev er Lock 3. Master Cylinder Rese rvoir / Cover 4. [...]

55 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n T rack W ARNING Oper ating t he snowmobile wit h a damaged t rac k incr eases t he possibilit y of t rack failur e, whic h could caus e loss of cont rol result ing in serious injury or deat h. Always inspect t he trac k for damage bef ore using t he vehic le. Use of trac tion produc ts suc[...]

56 PRE -RIDE IN SPECTI ON S Star t the E ngine and Check n Engine St op Switc h Check the auxilia ry shut-of f switch for proper opera tion. Push the switch down to stop the e ngine. Pull it up to allow resta rting. n Ignit ion Swit c h Make sure the e ngine stops when the ignition switch is turned to OFF . n T ether S witch If your mac hine has a [...]

CH OKE T OGGLE POS ITIONS OFF HALF ON FUL L ON 57 OPERATION Star ting the E ngine W ARNING Befor e st art ing the engine, always ref er t o all saf et y warnings pertaining t o snowm obile operat ion. Nev er st art y our snowm obile without chec king all com ponents to be s ure of proper operat ion. See Check Bef ore St art ing t he Engine beginnin[...]

58 OPERATION Star ting the E ngine Sta rti ng a W arm E ngine 1. T urn the key to the ON position. 2. P ull the engine stop switch up to the RUN position. 3. Grasp the recoil rope ha ndle and pull slowly until the rec oil engage s; then pull a bruptly . NOT E: I f the engine does not start on the firs t pull, slight ly depress the t hrot tle wit h [...]

59 OPERATION Engine B r eak -In Oil Injection System Alwa ys fill the oil tank when ref ueling. See pag e 63. CAUTION Serious engine damage can oc cur wit hout the pr oper lubric ation. Check t he oil tank level of t en during t he fir st tank of f uel. If t he oil level doesn’t go down, contact y our dealer immediately . Oil R ecom me ndations T[...]

60 OPERATION T rack W arm -Up W ARNING A loose t rac k or f lying debr is could c ause ser ious injury or deat h. Stand c lear of t he fr ont of t he machine and t he mov ing tr ack. Never hold t he snowmobile up or st and behind it while warming up the track. Do no t use excessive thro ttle during w arm-up o r when the t rack is f ree- hanging. B [...]

61 OPERATION Fuel W ARNING Gasoline is highly f lamm able and explosiv e under cer tain conditi ons. S Always exerc ise ext rem e caut ion whenever handling gas oline. S Always r efuel out doors or in a well- vent ilated ar ea. S Always tur n off t he engine befor e ref ueling. S Do not over fill t he t ank. Do not fill t he t ank neck . S Do not s[...]

62 OPERATION Fuel For peak per forma nce, Polaris rec ommends the use of 91 octane or higher fue l. Although 87 octane fuel is usable, some engine perf ormanc e will be lost and fue l economy will decr ease . Do not use fuel l ower th an 87 oct ane. CAUTION Operat ing with obs truct ed fuel syst ems will result in serious engine damage. Perfor m ma[...]

63 OPERATION Oil n Low Oil I ndicator Light The low oil indic ator light will a lert the opera tor if the oil level is low . V isually c hec k the oil leve l in the bottle. Add oil bef ore f urthe r opera tion of the snowmobile. S ee page 59 for oil re commenda tions. n Low Oil Level Maintaining the prope r oil le vel will pr eve nt system a era ti[...]

64 OPERATION n Engine Stop S wi tch Push down on the engine stop switch ( L ) to gr ound out the ignition and stop the e ngine quickly . Pull the switch up to the ON position to allow r estar ting. n Throttle S afety Switch The throttle saf ety switc h is designed to stop the engine w hene ver a ll pressur e is remove d from the throttle leve r and[...]

65 OPERATION Throttle Lever W ARNING An impr operly f unct ioning thr ott le lever may cause er rat ic machine behavior and loss of c ontr ol, whic h could res ult in serious injur y or death. I f t he throt t le lever does not work pr operly , DO NOT st art t he engine. If the engine stops abr uptly when the throttle le ver is relea sed: 1. T urn [...]

66 OPERATION Em er gency Stoppi ng The following cha rt lists methods for stopping the snowmobile in the even t of an emer genc y . See page 64 for more infor mation about the engine stop sw itch a nd throttle sa fe ty switch. SYSTEM WHA T IT DOES THR OTTLE CONDI TI O N Igni ti on Swit ch Int err upt s igni ti on cir cuit All Brake Sl ows jackshaf [...]

67 OPERATION Em ergency S tar ting If the rec oil star ter s ystem fa ils, an eme r gen cy star t stra p is provided in the tool kit. 1. Open the hood. 2. Rem ov e th e left s ide p anel . 3. Using t he belt removal tool, follow the directions on the air box to relie ve belt tension. 4. S tarting at one of the tower struts, wind the strap counter c[...]

68 OPERATION Electr onic Rever se (PE RC t ) Electr onic reve rse will activa te only if the engine RP M is below 4000. W ARNING Im proper r evers e operat ion, ev en at low s peeds, may c ause loss of cont rol, r esult ing in serious injury or death. Damage will occ ur to t he chaincas e or t ransm ission if s hift ing is at tem pted when t he eng[...]

69 OPERATION Daily Storage At th e end of each ride, p ark the snowmobile on a level surfac e and support it a t the re ar with an appropr iate tra ck stand. The trac k should be suspende d approxima tely 4 ″ (10 cm) of f the ground. Remove the key and cove r the mach in e. T owing W ARNING Object s t owed wit h a rope have no br aking power and [...]

70 MAINTENANCE Polar is Recom m ended Maintenance Pr ogr am T o ensure many trouble-free miles of snowmobiling e njoyment, follow rec ommende d regula r maintena nce a nd perfor m service c hec ks as outlined in this manua l. Reco rd mainte nanc e a nd servic e in the Maintena nce L og beginning on page 120. The rec ommende d maintenanc e sche dule[...]

71 MAINTENANCE Per iodic Maintenance Inter val T able The following char t is a guide based on ave rage r iding conditions. Y ou may ne ed to incr ease fre quenc y based on r iding conditions. When ins pect i on rev eals t he need for rep lacem ent part s, al way s us e gen ui ne Polaris pa rts, ava ilable from your Polaris de aler . See P Frequenc[...]

72 MAINTENANCE Per iodic Maintenance Inter val T able See P Frequency Item Page 150 mi. (240 k m) 500 mi. (800 k m) 1000 mi. (1600 k m) 2000 mi. (3200 k m) Pre- Season Brakes Hose Rou tin g - I I I I Hos e Condition - I I I I Fluid Leak s - I I I I Brak e Pads 88 I I I I Brake Disc - I I I I Parking Brakes 54 I I I I Brak e Sy s tem 51, 88 I Brak e[...]

73 MAINTENANCE Per iodic Maintenance Inter val T able See Frequency Item Page 150 mi. (240 k m) 500 mi. (800 k m) 1000 mi. (1600 k m) 2000 mi. (3200 k m) Pre- Season CHASSIS Sk i T oe A lignment - I I I Sus pension Mounting Bolts - I I I I I Steering F astener s - I I I I C Rear Sus pens ion Fas teners - I I I I I Sus pension S hoc k O il - I I I I[...]

74 MAINTENANCE Lubri cation Front S uspe nsion The fr ont suspension and ste ering c omponents do not re quire lubrica tion. Rear Suspension Lubrica te the suspension pivot shaf ts with Polar is Premium All Se ason Gre ase a t 500 miles (800 km) initially , every 1000 mile s (1600 km) after th at, an d befor e off-season st orag e each year . Lack [...]

+ + 75 MAINTENANCE Lubri cation Driveshaft Bear ing Injec t grea se into the f itting on the speedome ter sensor housing until grea se pur ges from the seal on the inside of the tunnel. This should take a pproxima tely two pumps. Do not use more than four pumps. Throttl e Cable Lubric ate the thro ttle cab le lightly with grea se or oil. W ith the [...]

1 2 3 76 MAINTENANCE Lubri cation n Chaincase Oil Check the cha inca se oil le vel a t the interv als outlined in the maintena nce c harts beginning on page 71. The sight glass (1) is locat ed o n t he l ower rear o f the cha inca se. Mainta in the o il level a t or slightly below the ce nter of the sight glass (2). Change the chain case o il after[...]

4 77 MAINTENANCE Lubri cation Chaincase Oil Oil Chan ge 1. Position t he vehic le on a level surface. 2. Remove the drain plug (4) and drain the oil into a dr ain pan. Allow the oil to drain comple tely 3. Install a new sealing washe r on the drain plug. NOT E: T he sealing sur fac es on t he drain plug and t he oil tank should be clean and f ree o[...]

78 MAINTENANCE General Maintenance Spa rk P lugs A new e ngine c an ca use te mporar y spark plug f ouling due to the prese rvative adde d during the asse mbly proc ess. A void prolonge d idle speed s, which cause plug fouling and c arboniz ation. Change the spark plugs e very 2000- 2500 miles (3200- 4000 km). CAUTION Using non-r ecomm ended spark [...]

2 79 MAINTENANCE General Maintenance Spa rk P lugs Spark plug c ondition is indicative of engine opera tion. The spar k plug firing end c ondition should be r ead a fter the engine has bee n war med up and t he veh icl e has been d riv en at hi gh er speed s. Imm edi atel y check th e spark p lug fo r correct col or . W ARNING A hot exhaust syst em[...]

+ 80 MAINTENANCE General Maintenance Intake Filters The intak e foam filte r limits snow ingestion into the inta ke system. When ope rating in loose powder snow , check the top of the foam filte r periodic ally to r emove a ny accum ul ati on o f sn ow . CAUTION Operat ing t he snowmobile wit h t he intak e filt ers remov ed may cause c arburet or [...]

81 MAINTENANCE General Maintenance Oil Filter/Oil Lines Inspec t oil line c ondition at 1000 miles (1600 km). The oil filter should be cha nged a nnually or e very 1000 miles (1600 km). The oil filter is locat ed o n t he l eft s id e of t he b ul khead behind the drive clutc h. Have your de aler pe rfor m the filter cha nge and ble eding oper atio[...]

82 MAINTENANCE General Maintenance Car bur etor The n um ber s tam ped in th e end of t he m ain j et i nd icat es t he j et s i ze. The jet installe d at the time of manufac ture is not n eces sari ly co rrect for your ele vation. It’ s your dealer ’ s responsibility to make sur e the cor re ct ma in jet is insta lled. CAUTION Operat ing t he [...]

83 MAINTENANCE General Maintenance Car bur etor W ater /S edim ent T ra p Most Polaris snowmobiles conta in patente d ca rbure tor bowl water/ sedi m ent t raps lo cated at t he bot to m of each carburet or . The trap, consisting of a hose with a plug, should be drained about eve ry 1000 miles (1600 km) and inspec ted for contamina tion. W ARNING W[...]

84 MAINTENANCE General Maintenance Coola nt The coolan t supplied in the system is a 60/40 mixture of ethylene -glyc ol and distille d wate r . This mixture pr ovides pr otec tion against freezing. Contact your dealer i f greater protect io n is required. Use Prem iu m 60 /4 0 anti -freeze cool ant , wh ich i s alread y prem ix ed and ready to u se[...]

85 MAINTENANCE General Maintenance Coola nt High T em per atur e Indicator Li ght The high temper ature indic ator light will illuminate when engine coolant te mpera ture be comes too hot for safe continued ope ra tion of the engine. If you must drive your machine a fter the high temper ature indicator light has come on, drive slowly and stop fr eq[...]

86 MAINTENANCE General Maintenance Bleeding the Cooling System Use of a non-standa rd pressur e cap will not allow the recover y system to fun cti on p roperl y . If the press ure cap need s repl acemen t, co ntact your dealer f or the corr ect part. W ARNING Steam and hot liquids will caus e serious burns to y our sk in. Neve r bleed the co oli ng[...]

1 2 87 MAINTENANCE General Maintenance Drive Chain T e nsion Chec k drive c hain te nsion wee kly and befo re each lon g tri p. T o ob tai n correct chai n t ens ion : 1. Rotate the driven clutc h counter clockwise to move all chai n sl ack to t he ten si on er sid e. Lock the brake le ver lock, or have an assista nt hold the brake leve r firmly . [...]

88 MAINTENANCE General Maintenance n Hydraulic Br ake Inspection Insp ect t he b rake lev er reserv e before each us e of t he s nowm ob il e. See page 53. Brak e pads m ust be r eplaced when th e brak e pad m ateri al becom es thinner tha n the bac king plate (appr oximate ly 1/16 ″ ). A kit is ava ilable for re placing brak e pads. See your dea[...]

89 MAINTENANCE General Maintenance Br ake Fl uid W ARNING Aft er opening a bot t le of br ake f luid, alway s disc ard any unus ed port ion. Nev er st ore or use a part ial bot tle. Brake f luid is hygros copic, meaning it rapidly absor bs mois tur e from t he air . The m oistur e causes t he boiling tem perat ure of the br ake f luid to drop, whic[...]

90 MAINTENANCE General Maintenance Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spongy brake le ver a ction. Bleed the system befor e opera ting the snowmobile. W ARNING Oper ating t he vehicle wit h a spongy brak e lever c an result in loss of br akes, which c ould cause an ac cident and lead to s erious injury[...]

2 1 3 91 MAINTENANCE General Maintenance Rem ovi ng Hal ogen Bul bs NOT E: Do not t ouch a halogen bulb with bar e finger s. Oil fr om sk in leaves a r esidue, c ausing a hot spot t hat will s hort en the lif e of t he lamp. I f f ingers do touc h the bulb, clean it wit h an alcohol-m oistened t owel. 1. Remove the plenum covering from the head lig[...]

92 MAINTENANCE General Maintenance Clutch System Peri od ical ly in sp ect cl ut ch sh eaves for d amage, wear o r bel t res id ue. T o mainta in optimum per forma nce , clea n with non-oil ba sed c lea ners such as isopr opyl alcohol. W ARNING If you bec ome aware of higher t han norm al clut ch engagement or an unusual vibr ation or shif t pat t [...]

+ 93 MAINTENANCE General Maintenance n Dr ive B elt C ondition Periodic ally c hec k the condition a nd tension of the drive belt, and always car ry a spare . Inspect the belt for signs of excessive wea r: fra yed edge s, missing cogs, cra cks and e xce ssive loosene ss. Replac e the belt if any of these conditions ex ist. See Drive Belt T roublesh[...]

94 MAINTENANCE General Maintenance Drive Belt Installation 1. Drop the drive belt over the drive c lutch a nd pull back the sl ack. NOT E: T o ens ure sat isf act ory belt life, inst all belt s so t hey operat e in the s ame direct ion of r otat ion by positioning t he identif icat ion numbers so that you c an read t hem. If required, separ ate t h[...]

A B .010 ″ -. 030 ″ (. 25-. 75mm) 95 MAINTENANCE General Maintenance n Drive B elt Deflection Measu re bel t defl ecti on wi t h bot h clut ches at res t and i n th eir ful l neutra l position. Place a straight edge on the belt (A) and apply downwa rd pre ssure while measur ing at point B. This measur ement should be 1 1/4” (3.2 cm). Dr ive B[...]

2 1 3 6 4 5 96 MAINTENANCE General Maintenance T ool Kit A tool kit is include d with each m achi ne for em ergency and ro ut in e mai nt enan ce. Always kee p the tool kit with the snowmobile. 1. Emer gency Star t Strap 2. L-W rench 3. S park Plug W ren ch/ Screwd riv er 4. S cissor Stop W rench 5. Combination W rench 6. Open End W rench Fall T un[...]

L 97 MAINTENANCE T rack Maintenance T rack Inspection W ARNING Brok en tr ack r ods are a s erious s afet y haz ard. They can c ause a rot ating t rack t o come off the m achine, which c ould cause s erious injury or death. Never operat e wit h a damaged t rack . Nev er rot ate a dam aged tr ack under power . 1. Using a hoist, safely lift a nd supp[...]

98 MAINTENANCE T rack Maintenance W ARNING Moving par ts can cut and cr ush body part s. When perf orming t he check s and adjust ment s rec omm ended on the f ollowing pages, st ay clear of all mov ing parts. Never perf orm t rac k measur ement or adjust ment s wit h the engine r unning. T rack T ensio n T rack a djustment is critic al for prope r[...]

99 MAINTENANCE T rack Maintenance T rack T ensio n I f t he tr ac k nee ds adjust m ent : 5. Loosen the rear idle r shaft bolt (D). 6. Loosen the locknuts (A). 7. T ighten or loose n the track ad jus ti ng s crews (B ) as nec essa ry to provide equal a djustment on both sides of the trac k. 8. R epeat t he measu remen t on the other side of the tra[...]

+ 100 MAINTENANCE T rack Maintenance n T rack Alignment Peri od ical ly ch eck th at th e track is cen tere d and r unning even ly on the slide rails. Misalignme nt wil l cau se exces si ve wear t o t he tra ck a nd slide r ail. 1. S afe ly support the rear of the mac hine with the trac k of f the ground. 2. S tart the engine and apply a small amou[...]

+ + + + 101 MAINTENANCE Steer ing System Steering Inspection and Adjustment Each week, or b efore a long ri de, ch eck all s teeri ng s ys tem fas ten ers and ti gh ten i f necess ary .[...]

X Y 10 ″ 10 ″ 102 MAINTENANCE Steer ing System Sk i Ali gnme nt W ARNING Im proper ski alignment or adjust ment may caus e loss of steering contr ol, r esult ing in serious injury or deat h. Do not at tem pt t o change the s ki alignm ent or camber adjust ment . S ee your Polaris dealer. W ith the handle bar s in a straight a hea d position, an[...]

+ 103 MAINTENANCE Steer ing System n Ski S kags W ARNING Worn skis and/ or skags will adver sely affec t handling. Loss of vehicle cont rol may r esult , causing ser ious injury or deat h. See your dealer ’s studding char t f or r ecomm ended skags . I f you install longer or m ore aggres sive c arbide sk ags t han the or iginal equipment , it ma[...]

+ 7/16 ″ (1.1 cm) 104 MAINTENANCE Steer ing System n Rail Slide Measur e slide thickness at sever al points along the rail. Have your de aler repla ce the slide w hen it’ s w o r nd o w nt ot h et o po f the wea r groove ( + ). Do not operate the snowmobile if slide thickne ss mea sures le ss than 7/16 ″ (1.1 cm ). Suspension Maintenance n Pr[...]

105 MAINTENANCE Suspension Maintenance Extended S tor age Of f-se ason or extende d storage of your snowmobile re quires pre ventive measur es to a id against de terior ation and to pr olong the use ful life of many compone nts. See page 108 for the part numbers of Polaris products. Cleaning and Preser vation Proper stor age sta rts with cle aning,[...]

106 MAINTENANCE Extended S tor age Bearings Grea se the jacksha ft and drive shaf t clutch side bearings with Polaris Premium A ll-Sea son Gr ea se or a similar h igh quality gre ase to pre vent corros io n. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubrica te clutc h compone nts, excep t the driven c lu[...]

107 MAINTENANCE Extended S tor age Electr ical Connections Repl ace worn or frayed elect rical wi re and co nnect ors . B e su re wiri ng harne ss is properly sec ured a way fr om sharp e dges, steer ing linkage, moving parts, and hot exha ust parts. T ra ck and S uspensi on Modera te tr ack te nsion should be mainta ined during summe r storage . T[...]

108 POLARIS PRODUCTS Part No. Descri pt io n Engine Lubr icant s 2870791 Fogging Oi l ( 12 oz. Aerosol) 2871098 Premi um 2- Cycle E ngine Oi l ( qt. ) 2871097 Premi um 2- Cycle E ngine Oi l ( gal. ) 2871240 Premi um 2- Cycle E ngine Oi l ( 2.5 gal . ) 2871721 Premi um Gol d Synt heti c 2-Cycl e Engine Oi l (qt. ) 2871722 Premi um Gol d Synt heti c [...]

109 TROUBLE S HOOTIN G Engine T r oubleshooti ng CAUTIO N: Unless you have e xper ience and training in two-c ycle engine re pair , see your dealer if te chnica l problems arise . Proble m Proba ble Ca us e Solutio n Err a ti c e ngine oper a ti ng R P M d u r i n g Driv e clutch bin d in g S SEE YOUR DEALER. R P M d ur i ng acceleration or loa d v[...]

11 0 TROUBLE S HOOTIN G Engine T r oubleshooti ng Proble m Proba ble C aus e Solution Noise i n drive system Broke n drive c lutc h com ponent s S SEE YOUR DEALER. Bearin g failu re/ chain case, jack sh aft, or fr ont dri ve s ha ft S SEE YOUR DEALER. Driv e b elt su rface flat spot s S Insp ect an d replace as n eed ed . Driv e chain loo se S Insp[...]

111 TROUBLE S HOOTIN G Engine T r oubleshooti ng Proble m Proba ble C aus e Solution Engine t ur ns bu t fails to start Fau lty ig nitio n S In stall n ew sp ark plu g (s). If en g ine still fails to start, ch eck for sp ark . If th ere’ s no spar k, SEE YOUR DEALER. No fue l to e ngi ne S Ma ke sur e t he fue l val ve i s on. S Us e the c hoke .[...]

11 2 TROUBLE S HOOTIN G Suspension T r oubleshooting Probl em Solut i on (per for m onl y one change at a ti me) Rear su sp en sio n bo tto ms to o easily - V e ri f y sa g di me ns ion ( s ee page 42). Ad ju st torsio n sprin g b lo ck s or in stall o p tion al to rsio n sprin g s to achiev e correct sag dimen sio n s. - I nc re a se s hock compr [...]

11 3 TROUBLE S HOOTIN G Dr ive B elt T roubl eshooting Be lt W ea r/B urn D iagnos is Causes Solutions Driv ing at low RPM S Driv e at h ig h er RP Ms. G ear th e mach in e d o wn . C h eck bel t de fl e c ti on. Insu fficient w arm-u p S W ar m the e ngi ne at l e as t f ive m inut e s. T ake the dr i ve be lt of f the m ac hi ne in e xt re me l y[...]

11 4 WARRANTY Ser vic e And Warranty I nform ati on Obtaining Service and W arranty Assistance Read and unde rstand the ser vice da ta and the Polaris war ranty informa tion containe d in this manual. Contact your Polaris dea ler f or replacem ent part s, s ervi ce or warrant y . Y our deal er receiv es freq uent updates on c hange s, modifications[...]

11 5 WARRANTY Li mit e d W arra nt y Pola r is S al e s Inc . , 2100 Highwa y 55, Medi na , MN 55340, provi de s a ONE YEAR LIM - ITED W ARRANTY on all c ompone nts of t he Pola ris s nowmobi le a ga ins t de fe c ts i n ma te r ia l or wor kma nshi p. This war r ant y cove r s the pa r ts a nd la bor cha r ges f or re pa ir or replacem en t o f d [...]

11 6 WARRANTY Limita tions of warranti es a nd remedie s ALL IMPLI ED W ARRANTIES (I NCLUDING BUT NOT LI MITED T O THE IM- PLIED W ARRANTIES OF MERCHANT ABILITY AND FI TNESS FOR A P AR TI CU- LAR PURPOSE) ARE LIMI TED I N DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAI MS ALL EXPRESS W AR- RA NT IE S NO T S T A T ED IN T [...]

11 7 WARRANTY Conditions and Ex cl usi ons In or de r t o qua li f y for war r ant y , the produc t mus t ha ve been pr ope rl y s e t up a nd t es t e d by a Po laris D ealer (if ap plicab le). F ailu re o f an y d ealer to perfo rm th e req u ired veh icle P re- De li ve ry Ins pe ct i on, per f orm a ll a ppl ic a ble s e rvi c e bull e t ins a [...]

11 8 WARRANTY Pol ar is Se cond Y ear E ngine S er vice C ontr act Sec ond Y e ar Engine Servi c e Cont r a ct is s tanda r d on al l el i gibl e new a nd unuse d snow mobil e s tha t we re Snow Chec ke d thr ough a n aut hor iz e d Pola ris dea le r duri ng t he Ma rc h/ Apr il Snow Chec k promot ion. The fre e Se c ond Y e ar Engi ne Se rvi c e C[...]

11 9 WARRANTY Exported V ehicles EXCEPT WHERE SPECIFI CALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THI S VEHICLE I F IT I S SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. Th is po licy d oes no t app ly to v eh icles that hav e received auth o rizatio n fo r e xpor t f rom Pola r is[...]

120 MAINTENANCE LOG Present thi s sect ion of your manual to your deal er each time your snowmobile is service d. This will provide you and future owner s with an accurate l og of m ain ten ance and serv ices p erform ed on t he snowmobile. DA TE MIL ES ( KM) TECHNICIAN SER VICE PERFOR MED / COMMENTS 150 mi. (240 km ) 500 mi. (800 km ) 1000 mi. (16[...]

121 MAINTENANCE LOG DA TE MIL ES ( KM) TECHNICIAN SER VICE PERFOR MED / COMMENTS[...]

122 INDEX A Accesso ries 4 7 .................... Ad ju stable H ead lig ht s 2 8 ............ A v alan ch es 14 .................... B Bea r ings 106 ..................... Bef or e Sta r ti ng the Engine 51-55 ...... Bel t T r ouble s hooti ng 113 ........... Bleed in g th e Coo lin g Sy stem 86 ...... Bleed in g t he H y d raulic B rak e S ystem [...]

123 INDEX H Ha loge n Bul bs 91 ................. Ha ndle ba r Adj ust me nt s 46 ........... Ha ndle ba r Angl e 46 ................ Han d leb ar Po sitio n 46 .............. Head lig h ts 28 ..................... High T e mpe ra t ure I ndi ca t or 85 ....... Hydra ul ic Br a ke Ins pe ct i on 88 ........ I Ic e a nd Snow Buil d-up 15 ...........[...]

124 INDEX S Sta r ti ng, Eme r gency 67 ............. Ste e ri ng Adj us tme nt 101 ............ Ste e ri ng I nspe c t ion 101 ............. Ste e ri ng Syst e m 52, 101-104 ......... Stoppi ng 66 ...................... Stor a ge 69, 105- 107 ................ Stor a ge Compa rt me nt 28 ............ Studs 48 ......................... Su rv iv al P[...]