Polaris 600 HO RMK 155 manual

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WARNING Read, understand, and follow all of the in structions and safe ty precautions in this manual and on all produ ct labels. F ailure to follow the safety precautions could result in serious injury or dea th. WARNING The engine exhaust from this product co ntains chemicals known to th e State of California to cau se cancer , birth defects or ot[...]

1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e p roudly produce an exciting line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles W e believe Polaris sets a standard of excell ence for a ll[...]

2 POLARIS and POLARIS TH E W A Y OU T are regist ered trademarks of Pola ris Indus- tries Inc. Copyright 2006 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discre[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This section contains helpful info rmation for own ers and drivers and illustrates the location of important identification numbers that should be recorded in the owner ’ s manual. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 [...]

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5 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 th e snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations. Y our model may differ . Follow the maintenance program out[...]

6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourage state and provin cial governments across the sn ow- belt to adopt rigorous safety traini ng programs that encourage protection of our environment, includ ing wildlife and vegetation. Snowmobile clubs and o ther orga[...]

7 INTRODUCTION V ehicle Identification Numbers Record your snowmobile’ s identific ation numbers and k ey number in the spaces provided below . The key nu mber is stamped on the spare key . The number on the rubber -coated key is in the form of raised dots. Remove the spare key and store it in a safe place. An ignition key can be duplicated only [...]

8 SAFETY Operator Safety The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safe ty alert symbol , on your vehicle or in thi s manual, alerts you to the potential for injury . [...]

9 SAFETY Operator Safety Follow the recommended mainte nance program outlin ed beginning on page 71 of this manual to ensure that all critical co mponents on the snowmobile are thoroughl y inspected by your dealer at specific mileage intervals. WAR N I N G Driving a snowmobile requires your full attenti on. DO NOT drink alcohol or use drugs or medi[...]

10 SAFETY Operator Safety Stay Clear of T rack Y our snowmobile is propelled by a revo lving track that must be part ially exposed for proper operation. Stay Clear of Engine Never attempt adjustments w ith the engin e running. T urn of f the igni- tion, raise the hood, make the adju stment, secure shields and guards, secure the hood, and then resta[...]

11 SAFETY Operator Safety Riding Position Operating a snowmobile requires sk ill and balance for proper control. Rider positions may vary with expe rience; 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 throt tle, brake and steering control. Surviv[...]

12 SAFETY Operator Safety Riding Apparel Helmet W earing a helmet can prevent a sever e head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Ca nada bear a U.S. Dep artment of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania[...]

13 SAFETY Operator Safety Disabled Operators Safe operation of this rid er-active vehi cle requires good judgement and physical skills. Rider Capacity Y our Polaris snowmobile is designed for a single rider only . Do not carry a passenger . Excessive Speed Always observe all state an d local laws governing snowmobile opera- tion and speed limits. A[...]

14 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. Guy wires on utility poles are also difficult to disti[...]

15 SAFETY Operator Safety Avalanches Snowmobilers should always be prop erly trained and equipped before traveling in mountainous terrain: • T ake an av alanche cl ass • T ravel with experienced people • T ravel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon. Y ou don’t have to be snowmo[...]

16 SAFETY Operator Safety I ce and Snow Build-up Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If dif ficulty is encountered, remove ice and snow build-up that may be obstru cting the steering linkage. Driving Downhill When riding downhill, shift your wei[...]

17 SAFETY Operator Safety Driving on Slippery Surfaces Driving in Hilly T errain Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you mu st cross the face of a slope, keep your weight on the uphill side of the snowmobile to maintain proper balance and av oid possible rollover[...]

18 SAFETY Operator Safety Drive Belt Do not operate the engine wi th the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer . Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do not operate the engine with the intake silencer or filter [...]

19 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrica tion for the power slide suspension and, on liquid cooled mo dels, coo ling for the engine, adequate snow cover is a requirement for operation of your snowmobile. Driving in too little snow will result in excessive we ar and damage to the slide rail, track and[...]

20 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the mos t docile condi- tions may become dangerous if oper ators drive improperly . If you ’re new to snowmobiling, acquaint your self with the machine and with what it will and won’t do under various conditions. Even seasoned driv- ers should spend so[...]

21 SAFETY Operator Safety Windchill/T emperature Charts The following informatio n is provided to help you determine when tem- peratures become da ngerous for riding. WIND CHILL CHART ( ° F) WIND CHILL CHART ( ° C) Wind Speed in MPH Actual Thermometer Reading ( _ F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Equivalent T emperatu[...]

22 SAFETY Safety Decals and Locations W arning decals hav e been placed on the snowmobile for you r protec- tion. Read and follow the instructions of the deca ls and other warnings on the snowmobile carefully . If any of the decals depicted in this ma nual differ from the decals on your snow mobile, always read and follow the instructions of the de[...]

23 SAFETY Safety Decals and Locations “No P assenger” Warning Snowmobiles design ed for only a single rider have a warning de cal on the console below the steering post. WARNING This vehi cle is desi gned for operator only . “NO P AS SENGER” T rack W arning The track warning decal is on the rear of the tunnel. WARNING Stay clear of track. D[...]

24 SAFETY Safety Decals and Locations Reverse Warning Polaris snowmobiles equipped with electric reverse have a reve rse warning decal on th e console. WARNING Reverse operation, even at lo w speeds, can cause loss of contro l resulting in serious injury or death. T o avoid loss of control, always: • Look behind before and while backing up. • A[...]

25 SAFETY Safety Decals and Locations Operation W arning (continued from previous page) • Excessive speed, especially at night or with limited visibility , can result in insuffici ent time for you to react to terrain ch anges, to avoid unexpected obstacles , or to stop safely . • Never consume alcoho l or drugs before or while operating this ve[...]

26 FEA TURES 1. Front Bumper 2. Hood 3. Headlight 4. Windshield 5. Mountain Bar (if equipped) 6. Handlebar 7. Seat 8. T a illights 9. Rear Bumper 10. Snow Flap 11. T rack 12. T ool Storage (600) 13. Suspension 14. T unnel 15. Side P anel 16. Ski 17. Nosepan 1 2 17 11 12 10 9 16 6 5 4 3 7 8 13 14 15[...]

27 FEA TURES 1. F uel Filler Cap 2. Ignition Switch 3. MFD (Multi-F unction Display) 4. Engine Stop Switch 5. Throttle Control 6. Recoil Starter Handle 7. Hood Hold-Down Straps 8. Brake Lever 9. Park ing Brake 10. Handlebar Gr ip Warmer Switch 11. Thumbwarmer Switch 12. Electronic Reverse Bu tton 13. MFD Control 14. Headlight Dimmer Switch 1 2 8 3 [...]

28 FEA TURES Accessory Cargo System The maximum weight capacity for the rear cargo area is 15 lbs. (7 kg). Always secure car go before operating. Do not exceed the cargo weight limit. Do not allow a passenger to sit on the seat back or the cargo area. Adjustable Steering The adjustable steering system allows you to adjust the handlebar posi- tion t[...]

29 FEA TURES Detonation Elimination T echnology (DET) A detonation sensor monitors the engi ne and responds to detonatio n by automatically reducing the engine timin g and adding fuel. This results in decreased engine RPM and performance. DET T roubleshooting Use this chart to determine causes an d solutions for detonation. If none of these conditi[...]

30 FEA TURES Instrumentation MFD Component Identification Item 1 Analog Gauge (if equipped) 2 Digital Gauge 3 Check Engine Indicator 4 Low Oil Indicator 5 High T emp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator 1 2 3 5 6 7 8 4[...]

31 FEA TURES Instrumentation Digital Display Identification Item 1 RPM or Speed Altitude (if equipp ed) Service Interval 2 Electrical System V oltage Level 3 MAX - Maximum MPH/ KPH or RPM MPH - Miles per hour KPH - Kilometers pe r hour RPM - Engine crankshaft revolutions per minute 4 Air T emp (if equipped) Engine T e mp Degrees Celsius Degrees F a[...]

32 FEA TURES Instrumentation MFD Settings The MFD Control Switch allows you to set the MFD display to your preferences. The rocker switch has a MODE button (top) and a SET button (bottom). Specific instructions are outli ned on the following pages. Standard vs. Metric The MFD will display either standard or metric units of measurement. While viewin[...]

33 FEA TURES 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 cycl e through the program’ s screens. Pe rforman[...]

34 FEA TURES Instrumentation MFD Digital Display Programs Pe rformance Program T rip Settings T rip 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. The T rip F od[...]

35 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram Air T e mperature (accessory) The MFD displays actual air temperature. Press and hold the MODE switch for ten sec- onds to switch between standard and metric units of measurement. Altimeter (accessory) The rider can calibrate the altimeter for cur- rent atmospheric conditions[...]

36 FEA TURES 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 cy cle through the following screens: maximum vehicle speed, maximum[...]

37 FEA TURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge log s the number of engine hours accumulated between service reminders . When the logged hours reaches the desig- nated service interval (set by the user), the gauge provides a reminder that service is due. "SErVCE" will flash in [...]

38 FEA TURES Instrumentation Gauge Cleaning 1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. W ipe dry with clean, soft cloth. 2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution. Do not remove the electrical connecto rs or pro- tective rubber boot. Do not spray the back[...]

39 THE PERFECT FIT IQ F ront Suspension Adjustments Independent F ront Suspension (IFS) Break in the suspension for approx imately 150 miles (24 0 km) before making any fine-tuning adju stments. Settings will vary from rider to rider , depending on rider weight, vehicle speed, riding style, and trail cond itions. W e recommend starting with factory[...]

40 THE PERFECT FIT IQ F ront Suspension Adjustments Air Shocks W alker Evans air shocks can be adju sted for preload and valving. Please see your Polaris dealer for these adjustments. Standard Shocks The tension at which the shock coil spring is set is called spring preload. For the best ride, the suspension should be adjusted to use the full trave[...]

41 THE PERFECT FIT IQ F ront Suspension Adjustments F ront Shock Spring Preload (RMK Premium Only) Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. T o increas[...]

42 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail co nditions, and vehicle speed all af fect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However , all sus- pension des igns and adjust ments involve a compromise, or t [...]

43 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) T o set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper . This is measurement X. T ake this measurement with no rider and with the rear suspension at full extension. NOTE: The rear bumper may need to be l[...]

44 THE PERFECT FIT Rear Suspension Adjustments T orsion Spring Preload T o adjust rear torsion spring preloa d, rotate the three-position cam using the engine spark plug tool. Diff erent rate torsion springs are available if a firmer ride is desired. Contac t your dealer for more information. The following information is provided only as a guidelin[...]

45 THE PERFECT FIT Rear Suspension Adjustments Shock Compres sion V alving RMK Standard Rear T rack Shock The standard RMK rear track shock is an Arvin MPV Select shock that allows for adjustments to the compression valving. Adjustments are made by turning the adjustment scr ew located near the base of the shock. In half-turn increments, turn the s[...]

46 THE PERFECT FIT Handlebar Adjustments Handlebar position and handlebar angle can be adjusted to rider prefer- ence. After making handlebar adjustme nts, check to make sure wires are not pinched or kinked. Make sure the handlebars, brake lever and throt- tle lever operate smoothly and do not hit the gas tank, windshield or any other part of the v[...]

47 THE PERFECT FIT Handlebar Adjustments Handlebar Position 1. Loosen the four bolts on the bottom of the adjuster block. NOTE: If necessary , pry the blocks apart with a screwdr iver . 2. Adjust the handlebar forward or rearward to the desired position. 3. Tighten the bolts. Handlebar Angle 1. Loosen the four bolts on the top of the ad juster bloc[...]

48 THE PERFECT FIT Accessories Polaris offers a wide range of accesso ries for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessorie s on your Polaris snowmobile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • V oiding of warranty • Injury [...]

49 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on th e checklist for proper operation or condition before each use of the snowmobile. Pr ocedures 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 P age Drive Belt Condi tion 97 Steering System 53[...]

50 PRE-RIDE INSPECTIONS Check Before Starting the Engine Read and Understan d Y our Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjo yable snowmobiling experience. n Throttle Lever The throttle and brake are the primar y controls of your snowmobile. Always make sure both ar[...]

51 PRE-RIDE INSPECTIONS Check Before Starting the Engine n Recoil Rope Inspect the recoil rope and handle fo r exces sive wear , and make sure the knot securing the rope inside the ha ndle is secure. If excessive wear is found, see your Polaris dealer for replacement. n Brakes Always check the following items fo r proper operation before starting t[...]

52 PRE-RIDE INSPECTIONS Check Before Starting the Engine n P arking Brake Lever Lock Use the parking brake lever lock only when you want th e snowmobile to remain stationa ry; for example, when parked on an incline for a period of five minutes or les s. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Rese rvoir/ Cover 4. Fluid Level I[...]

53 PRE-RIDE INSPECTIONS Check Before Starting the Engine n Steering System Manually turn the skis completely to the right and to the left . If any dif- ficulty is encountered , remove any ice and snow build-up that may be obstructing the steering linkage. n T rack Inspection Use of traction products such as stud s increases the possibility of track[...]

54 PRE-RIDE INSPECTIONS Check Before Starting the Engine n Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Befo re beginning any snowmobile trip, a visual inspection will uncover po tential problems. Check the follow- ing items on a weekly basis or before any long tr[...]

55 PRE-RIDE INSPECTIONS Check After Starting the Engine n Engine S top Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine . Pull it up to allow restarting. n Ignition Switch Make sure the engine stops when th e ignition switch is turned to OF F . n Te t h e r S w i t c h If your machine has a te[...]

56 OPERA TION Starting the Engine Do not depress the throttle until the engine starts. 1. Turn the key to the ON position. 2. Pull the engine stop switch up to the RUN position. 3. Carbureted models: T urn the fuel valve on. If the engine is cold, flip the choke toggle to FULL ON before cranking. After the engine starts, flip the toggle to the OFF [...]

57 OPERA TION Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of gasoline with one p int of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injec- tion system, will assure pr[...]

58 OPERA TION Engine Break-In Oil Injection System Always fill the oil reservoir when refueling. Oil Recommendations This snowmobile is equipped with a variab le exhaust system (V ES). Engine lubrication comes from oil ad ded to the fuel and oil injection systems. Polaris recommends the us e of VES II 2 Cycle Oil for this engine. See page 112 for t[...]

59 OPERA TION T rack W arm-Up Follow these steps to ensure proper warm-up of the engine, drive train and track. 1. Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper . The track sh ould be approximately 4" (10 cm) of f the ground. 2. Start the engine and allow it to warm up two to three minutes. 3. Depre[...]

60 OPERA TION F uel Safety WAR N I N G Gasoline is h ighly flammable and e xplosive under certain con ditions. • Always exercise extreme caution w henever handling gasoli ne. • 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. • Do not[...]

61 OPERA TION Fu e l For peak performance, Po laris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor- mance will be lost and fuel econ omy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing mor e than 10% ethanol (including E85) . F uel System Deicers If you use non-o[...]

62 OPERA TION Oil n Low Oil Indicator Light The low oil indicator light will alert th e operator if the oil level is low . V isually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 58 for oi l recommendations. n Low Oil Level Maintaining the proper oil level w ill prevent system aeration and possi- ble loss[...]

63 OPERA TION n Engine 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. n Throttle Safety Switch The throttle safety switch is designed to stop the engi ne whenever all pressure is removed from the throttle lever and the throttle cabl[...]

64 OPERA TION n Throttle Lever If the engine stops abruptly when the throttle lever is released: 1. Turn the ignition switch to OFF . 2. V isually inspect the throttle cabl e and throttle body to determine what caused the safety switch to activate. 3. T est the throttle lever by compr essing and releasing it several times. The lever and cable must [...]

65 OPERA TION n Emergency Stoppi ng The following chart lists methods for stopping the snowmobile in the event of an emergency . See page 63 for more information about the engine stop switch. SYSTEM WHA T IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Engine Stop Switch Interrupts ignition circu[...]

66 OPERA TION Emergency Starting If the recoil starter system fails, an em er gency start strap is provided in the tool kit. 1. Op en the hood. 2. Remove the left side panel. 3. Using the belt removal tool, follow the directions on the air box to relieve belt tension. 4. Starting at one of the tower struts, wind the strap counterclockwise around th[...]

67 OPERA TION Electronic Reverse (PERC t ) Electronic reve rse will activate only if the engine RPM is below 4000. The maximum engine RPM will be 6000 when in reverse. Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind yo ur snow- mobile is clear . 3. Push the yellow reverse button on the left-hand con[...]

68 OPERA TION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4" (10 cm) of f the ground. Remove the key and cover the snowmobile. To w i n g If the snowmobile becomes inope rable and must be towed, and if it is[...]

69 MAINTENANCE Emission Control Information Any qualified repair shop or qualifie d person may maintain, replace, or repair the emission control device s or systems on your snowmobile. Emission Control Label Y our snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa-[...]

70 MAINTENANCE Emission Control Information Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited W arranty on page 125, and read th e maintenance section of your o wner's manual. Y ou are responsible for ensuring that the specified maintenance is per- formed, including the emission-rela ted maintenance outlined in [...]

71 MAINTENANCE P olaris Recommended Mainte nance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform se rvice checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log begin ning on page 127. The recommended maintenance schedul e on your snowmobi[...]

72 MAINTENANCE P eriodic Maintenance Interval T able The following chart is a guide based on average riding conditions. Y ou may need to increase frequency based on ri ding conditions. When inspection reveals the need for replacement parts , always use genuine Polaris parts, available from your Polaris dealer . I - Inspect (clean, adjust, tighten, [...]

73 MAINTENANCE P eriodic Maintenance Interval T able Item See Pag e Fr eq u e n c y 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season BRAKES Hose Routing -- II II Hose Condition -- II II Fluid Leaks -- II II Brake Pads 91 II II Brake Disc -- II II Parking Brake 52 II II Brake System 51, 91 I Brake Fluid 93 R FUEL M[...]

74 MAINTENANCE P eriodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessar y) C - Clean R - Replace L - Lubricate Item See Pag e Fr eq u e n c y 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season CHASSIS Ski T oe Alignment -- II I Suspension Mounting Bolts -- II I I I St[...]

75 MAINTENANCE Lubrication F ront Suspension The front suspension does not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Pr emium All Season Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 72 and before sea sonal storage. When operating in heavy , wet snow conditions, l[...]

76 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into th e fitting on the speed- ometer sensor housing until grease pur ges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable lightly with grease or oil. W ith the engine off, tur[...]

77 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil leve l at the intervals outlined in the maintenance charts beginning on page 71. The sight glass is located on th e lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass. Change the chaincase oil after the first 500 miles (800 km), th[...]

78 MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug and drain the oil into a drain pan. Allow the oil to drain completely . 3. Clean off all metal shavings from the plug. 4. Install a new sealing washer on the drain plug. NOTE: The sealing surfac es on the drain plug and the oil t[...]

79 MAINTENANCE Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has b een warmed up and the vehicle has been driven at higher spe eds. Immediately check the spark plug for correct color . NOTE: On carbureted models, i ncorrect fuel mixture can often cause a spa r[...]

80 MAINTENANCE Spark Plugs A new engine can cause temporary spar k plug fouling du e to the preser- vative added during the assembly p rocess. A void prolonged idle speeds, which cause plu g fouling and carbon iza tion. Change the spark plugs every 2000-2500 miles (32 00-4000 km). • Use recommended spark plug s with the proper gap. • Use only r[...]

81 MAINTENANCE Intake Filters The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow , check the top of the foam filter periodically to remove any accumulat ion of snow . CA UTION Operating the 600 RMK with the intake filters removed may cause carburetor icing. The resu lt will be poor fue l ec onom[...]

82 MAINTENANCE F uel Injectors (DRAGON RMK) All fuel injector service must be performed by an au thorized Polaris dealer . Do not attempt to clean or service the fuel injectors. Fu e l P u m p All fuel pump service must be pe rformed by an authorized Polaris dealer . Do not attempt to service the fuel pump. F uel Filter See your Polaris dealer for [...]

83 MAINTENANCE Carburetor (600 RMK) The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correc t for your elevation. It's your dealer's responsi bility to make sure the correct main jet is installed. Carburetor Adjustments (600 RMK) The frequency at which th[...]

84 MAINTENANCE Carburetor W ater/Sedi ment T rap (600 RMK) Most Polaris snowmobiles contain pa tented carburetor bowl water/sedi- ment traps located at the bottom of each carburetor . The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination. Cleaning Procedure 1. Turn the fuel va[...]

85 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance T able beginning on page 71. Always allow the engine and exhaust system to co ol co mpletely before inspecting. 1. Open the hood and ins pect the mu ffler and pipes for cracks or dam- age. 2. Check for weak or missing reta[...]

86 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-gly col and distilled water . This mix ture provides protection agains t freezing. Contact your dealer if greater protection is required. Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water [...]

87 MAINTENANCE Cooling System Coolant High T emperat ure Indicator Light The high temperature indicator light wi ll illuminate when engine cool- ant temperature becomes too hot for safe continued operation of the engine. If you must drive yo ur snow mobile after the high temperature indicator light has come on, drive slowly and stop frequently to a[...]

88 MAINTENANCE Cooling System Bleeding the Cooling System Use of a non-standard pressure cap will not allow the recovery system to function properly . If the pressure cap needs replacement, contact your dealer for the correct part. WAR N I N G Steam and hot liquids will cause serious burns to your skin. Never bl eed the cooling system or remove the[...]

89 MAINTENANCE Cooling System Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main- tenance T able begin ning on page 72. Perform the bleeding procedure when the engine is cold. 1. Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark. 2. Eleva te the front[...]

90 MAINTENANCE Drive Chain T e nsion Check drive chain tension weekly and before each long trip. T o obtain correct chai n tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly . 2. Loosen the adjuster bolt jam nut. 3. Finger t[...]

91 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever travel before eac h use of the sn owmobile. See page 51. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate, approximately 1/16" (1.5mm). A kit is avail- able for replacing brake pads. See your dealer . WAR N I N G Brake fai[...]

92 MAINTENANCE Brakes Brake Components •B r a k e D i s c • Bleed Screw •B r a k e L i n e • Brake Caliper • Brake Pad Material - Replace when thickness is less than 1/16" (1.5mm). Excessive Lever T ravel Hydraulic brakes are self- adjusting, but if excessive brake pad clearance develops (see page 91) bring the snow- mobile to an aut[...]

93 MAINTENANCE Brakes n Brake Fluid Replace brake fluid at least every two years with Polaris DOT 4 high tem- perature brake fluid. See page 1 12 for the part numbers of Polaris products. The brake fluid level can be seen through a plastic sight glass in the brake reservoir . If the fluid is suffi- cient, the sight glass will be black. If the sight[...]

94 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spon gy brake lever action. Bleed the system before operating the snowmobile. During the bleeding proc edure, keep the brake handle as leve l as possi- ble. The reservoir must be in this po sition to minimize the possibility of air entering the s[...]

95 MAINTENANCE Lights Removing Halogen Bulbs NOTE: Do not touch a halogen bul b with bare fingers. Oil from skin leave s a residue, causing a hot sp ot that will shorten the life of the lamp. If fi n- gers do touch the bulb, clean it wi th an alcohol-moistened towel. 1. Remove the plenum cov- ering from the headlight assembly . 2. Lift the rubber b[...]

96 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. T o maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. Clutch Alignment and Offset Clutch alignment offset i s important for maintaining optimum performance. See your Owner's Manual Supplement for the recom[...]

97 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition an d tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and exce ssive looseness. Replace the belt if any of these conditions exist. Se e Drive Belt T roubleshooting on page 11 7 . F[...]

98 MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operating in a forward motion. NOTE: For easier accessibility , make sure t he clutch tool access hole is visible between the 11:00 and 2:00 positions of the clutch sheave. 2. Turn the ignition key of f. W ait for the engine to come to a complete stop. 3. Lock the parking bra [...]

99 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: T o ensure satisfactory belt life, install belts so they opera te in the same direction of rotation b y positioning the identification numbers so that you can read them. If required, separate the sheaves as outlined in th[...]

100 MAINTENANCE T rack Replacement When replacing the track, always inst all a track having the lug size rec- ommended for your mo del. See your Polaris deale r . T rack Inspection 1. Using a hoist, safely lift and sup- port the rear of the snowmobile of f the ground. 2. Rotate the track by hand to check for damage. 3. Carefully examine the track a[...]

101 MAINTENANCE T rack Lubrication The slide rail requires adequate snow cover for suf ficient lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limite d lubrication, resulting in excessive wear . NOTE: T rack damage or failure caused by operation on ice or under other poor lubricatio[...]

102 MAINTENANCE T rack T ension T rack adjustment is critical for prop er handling. Always maintain cor- rect tension and alignment. NOTE: T ension adjustments should be mad e only after the track is warmed u p and limber . 1. Turn the engine off. 2. Lift the rear of the snowmobile and safely support it of f the ground . 3. Pla ce the recommended w[...]

103 MAINTENANCE T rack T ension If the track needs adjustment: 5. Loosen the rea r idler shaft bolt. 6. Loosen the lock nuts. 7. Tighten or loosen the track adjus ting screws as necessary to provide equal adjustment on bo th sides of the track. 8. Repeat the measurem ent on the other side of the track. NOTE: Check more frequently when the snowmobil[...]

104 MAINTENANCE n T rack Alignment Periodically check that the track is centered and running ev enly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the snowmobile with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly[...]

105 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fa stener s weekly and before a long r ide. T ighten any loose fasteners. + + + + +[...]

106 MAINTENANCE Steering System Ski Alignment W ith the handlebars in a st raight ahead position, and with veh icle weight compressing the suspension, measure from the straight e dge of the skis at the center of the sk i mounting bolt. The measurement between the skis at point X sh ould be 1/8" to 1/4" (3-6 mm) greater than the measuremen[...]

107 MAINTENANCE Steering System n Ski Skags Check skags before each use of the snowmobile to ensu re positive steer- ing characteristics. Skags must be replaced when worn to half their orig- inal diameter . NOTE: Carbide skag s must be replaced if any abnormal w ear or chipping is found. Skag Replacement NOTE: Some models ar e equipped with single [...]

108 MAINTENANCE Steering System n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum permissible slide thick- ness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Failure to do so may result in permanent damage to the track or[...]

109 MAINTENANCE 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 componen ts. See page 1 12 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, an d waxing the hood, chass[...]

110 MAINTENANCE Extended Storage Engine and Carburetor Protection (600 RMK) Proper preparation of the engine and fuel system is vital to the preven- tion of rust an d corrosion on precision engine p arts during storage. Whenever the machine is stored for a period of more than 60 days, the engine must be fogged with foggi ng oil. Follow the engine f[...]

111 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wi re and connec tors. Be sure wiring harness is properly secured awa y from sharp edges, steering linkage, moving parts, and hot exhaust pa rts. T rack and Suspension Moderate track tension should be ma intained during summer storage. The machine sh ould be s[...]

112 POL ARIS PRODUCTS Pa r t N o . Description Engine Lubrica nts 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycl e Engine Oil (qt.) 2871097 Premium 2-Cycl e Engine Oil (gal.) 2871240 Premium 2-Cycl e Engine Oil (2.5 gal.) 2871721 Premium Gold Synthe tic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle En gine Oil (gal.) [...]

113 TROUBLESHOOTING Engine T roubleshooting Unless you have experience and traini ng in two-cycle engine repair , see your dealer if technical problems arise. Problem Probable Ca use Solution Erratic engine oper- ating RPM during acceleration o r load variations Drive clutch binding • SEE YOUR DEALER. Driven clutch mal- function • SEE YOUR DEAL[...]

114 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Noise in drive sys- tem Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, jacks haft, or front drive shaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed. Drive chain loose • Inspect and adjust (or repla[...]

115 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Engine turns but fails to start Faulty ignition • Install new spark plug(s). If engine still fails to start, check for spark. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is on. • Use the choke. See page 56. • Make sure t [...]

116 TROUBLESHOOTING Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Set static sag (see page 43). Adjust torsion spring blocks or install optional torsion spri ngs to achieve correct sag dimensions. Rides too stiff in rear • Check for bindi ng suspension components and grease all pivot points. • Set static [...]

117 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPM. Gear the machine dow n. Check belt deflection. Insufficient warm-up • W arm the engine at least five minutes. T ake the drive belt off the ma chine in extremely cold weather and warm it up. Break machine loose fro[...]

118 W ARRANTY Service And W arra nty Information Obtaining Service and W arranty Assistance Read and understand the service data and the Polaris warranty informa- tion contained in this manual. Contact your Polaris dealer for replace- ment parts, service or warranty . Y our dealer receives frequent updates on changes, modifications and tips on snow[...]

119 WA RRANTY Service And W arra nty Information Polaris Anti- Theft System The Polaris anti-theft system (P A TS) monitoring program is designed to aid owners of registered snowmobil es in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying the prop er law enforcement officials, the ow[...]

120 W ARRANTY Limited W arranty Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, provides a ONE YEAR LIM- ITED W ARRANTY on all components of the Po laris snowmobile ag ainst defects in material or workmans hip. This warranty covers the parts and labor charges for repair or replacement of d efective parts that are cove red by this warranty .[...]

121 WA RRANTY Limitations of warranties and remedies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W AR- RANTIES NOT ST A TED IN THIS W ARRANTY . Some s[...]

122 W ARRANTY Conditions and Exclusions In order to qualify for warranty , the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required veh icle Pre-Delivery Inspection, perfor m all applicable servic e bulle tins and have the consumer sign the PDI form prior to delivery ma[...]

123 WA RRANTY Polaris Second Y ear Engine Service Contract Second Y e ar Engine Service C ontract is standard on all el igible new and unused snow- mobiles that were Snow Checked through an au thorized Polaris dealer during the March/April Snow Check promot ion. Th e free Second Y ear E ngine Service Contract is honored by all authorized Polaris sn[...]

124 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELL ING DEALER’S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers[...]

125 WA RRANTY Snowmobile Engine Emis sions Limited W arranty This snowmobile engine emi ssions limited warranty is in addition to the Polaris stan- dard limited warrant y for sn owmobiles. Polaris Industries Inc. warrants that the new engine, including all parts of its emission- control system, is desi gned, built and equipped so it c onforms to cu[...]

126 W ARRANTY Snowmobile Engine Emis sions Limited W arranty Some states do not allow lim itations on how long an implied warranty lasts, so the above limitation may not appl y if it is inconsistent with the controlling state la w . This limited warranty excludes failures not ca used by a defect in material or workmanship. This lim- ited warranty d[...]

127 MAINTENANCE L OG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners wit h an accurate log of maintenance and servi ces performed on the snowmobile. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi[...]

128 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

129 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

130 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 48 Apparel for Riding . . . . . . . . . . . . . . 12 Avalanches . . . . . . . . . . . . . . . . . . . . 15 B Brake Components. . . . . . . . . . . . . . 92 Brake Fluid . . . . . . . . . . . . . . . . . . . 93 Brake Inspection . . . . . . . . . . . . . . . 91 Brake Lever Feel . . . . . . [...]

131 INDEX L Lights . . . . . . . . . . . . . . . . . . . . . . . . 95 Limiter Stra p Position . . . . . . . . . . . . 44 Low Oil In dicator Light . . . . . . . . . . 62 Lubrication . . . . . . . . . . . . . . . . . 75-78 Lubrication Choke . . . . . . . . . . . . . . . . . . . . 76 Choke Cable . . . . . . . . . . . . . . . 76 Driveshaf t Bearing . .[...]

132 INDEX T Tether Swit ch . . . . . . . . . . . . . . . . . . 48 Throttle Lever . . . . . . . . . . . . . . 50, 64 Throttle Safety Switch . . . . . . . . 50, 63 Torque Stop . . . . . . . . . . . . . . . . . . . 99 Torsion Spring Preload . . . . . . . . . . 44 Towing . . . . . . . . . . . . . . . . . . . . . . . 68 Track Alignment . . . . . . . . .[...]