Polaris 600 HO Switchback manual

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For your nearest P olaris dealer , call 1-800-POL ARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone (763) 417-8650 F ax (763) 542-0599 Part No. 9920459 Rev 02 Printed in USA[...]

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

1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris enthusiasts. Be sure to visit us online at www .polarisindustries.com for the la test news, new product introduc- tions, upcoming events, car eer opportunities and more. Here at Polaris we proudly produce an exciting line of utility and recre- at[...]

2 POLARIS and POLARIS TH E W A Y OU T are registered trademarks of Polaris Indus- tries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. Copyright 2005 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 an[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6[...]

4 INTRODUCTION V ehicle Identification Numbers Record your snowmo bile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Y our key can be duplicated only by mating a Polaris key b lank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.[...]

5 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourage gove rnments to adopt rigorous safety training pro- grams that encourage protection of ou r environment, including wildlife and vegetation. Snowmobile clubs and o ther organizations are working together to pro- tect[...]

6 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 this manual, ale rts you to the potential for injury . [...]

7 SAFETY Operator Safety Follow the recommended mainte nance program beginning on page 82 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your d ealer at specific mileage intervals. WAR N I NG Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications befor[...]

8 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 with the en gine running. T urn off the igni- tion, raise the hood, make the adju stment, secure shields and guards, secure the hood, and then restart [...]

9 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmobiles, but un der many co nditions, the proper position is to be seated with both feet on the ru nning boards and both hands on th e handlebar grips for prop[...]

10 SAFETY Operator Safety Survival Preparation For your safety , always ride in a gr oup of other sno wmobilers. Always tell someone where you're going and how long you expect to be gon e. If it isn't possible to ride with others , and you must travel into remote areas, always carry survival equipm ent that's appropriat e to the cond[...]

11 SAFETY Operator Safety Disabled Operators Safe operation of this rid er-active vehicle requires good judgement and physical skills. Operators with cogn itive or physical disabilities have an increased risk of loss of control, wh ich could result in serious injury or death. Rider Capacity Y our Polaris snowmobile is designed for a single rider on[...]

12 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snow mobiling 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 d[...]

13 SAFETY Operator Safety Avalanches Snowmobilers should always be properl y 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 sno[...]

14 SAFETY Operator Safety Ice 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 le ft and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstru cting the steering linkage. NOTE: If your snowmobile is equipped with RIDER SELE C[...]

15 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weig ht to the rear of the machine and reduce your speed to a minimum. Ap ply just enough throttle to keep the clutch engaged, allow ing the engine 's compression to help slow the machine and keep it fro m rolling freely downhill. WAR N I NG When driving on long downhi[...]

16 SAFETY Operator Safety 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 must cross the face of a slope, keep your weight on the uphill side of the machine to maintain proper balance and av oid possible roll-over . Slow down when reaching the c[...]

17 SAFETY Operator Safety Drive Belt Do not operate the engine wi th the drive belt removed. Any servicing that requires op eration without a belt mu st be performed by your dealer . Operation of th e 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 filt[...]

18 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 machine. Driving in too lit- tle snow will result in excessive wea r and damage to the slide rail, track and/[...]

19 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the most 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 va rious conditions. Even seasoned driv- ers should sp[...]

20 SAFETY Operator Safety Windchill/T emperature Charts The following informatio n is provided to help you d etermine when tem- peratures become da ngerous for riding. WINDCHILL CHART ( _ F) WINDCHILL 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 emperature [...]

21 SAFETY Safety Decals and Locations W arning decals hav e been placed on the snowmobile for your p rotec- 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 man- ual dif fer from the decals on your snowmobil e, always read and follow the instructions of the [...]

22 SAFETY Safety Decals and Locations T rack W arning The track warning decal is on the rear of the tunnel: Stay clear of track. Do not sit on seat back. Entan glement with the track or a fall from seat back may result in severe injury or death. "No P assenger" W arning The "NO P ASSENGER" warning decal is on the console below t[...]

23 SAFETY Safety Decals and Locations Reverse Warning The reverse warning decal is located on the console below the wind- shield: WARNING Reverse operation, even at lo w speeds, can cause los s of control resulting in serious injury or death. T o avoid loss of control, always: • Look behind before and while backing up. • Avoid sharp turns . •[...]

24 SAFETY Safety Decals and Locations Operation W arning • T o avoid serious injury or death, read and unde rstand all warnings and the Owner's Manual before oper ation. If manu al is missing, con- tact a Polaris dealer for a replac ement. • This vehicle is capable of high speed s. Buried objects or uneven terrain can cause lo ss of contro[...]

25 FEA TURES 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Seat Storage Compartm ent 7. T aillights 8. Rear Bumper 9. Snow Flap 10. Suspension 11. T r ack 12. Console Storage Compartmen t (if equipped) 13. Skis 14. Nosepan 15. Front Bumper 5 11 2 3 4 10 9 13 14 15 1 12 8 7 6[...]

26 FEA TURES 1. F uel Filler Cap 2. RIDER SELECT (if equipped ) 3. Ignition Switch 4. Br ake Lever 5. Headlight Adjuster 6. MFD Gauge 7. Engine Stop Switch 8. Throttle Control 9. Hood Hold Down Straps 10. Recoil Starter Handle 11. C hoke Lever 12. Parking Brake 13. Handlebar Grip W armer Switch 14. Thumbwarmer Switch 15. Electroni c Reverse Button [...]

27 FEA TURES RIDER SELECT Adjusta ble Steering System The RIDER SELECT adjustable steering system (if equipped) allows you to adjust the handlebar positio n to fit your style of riding. Setting Positio n Riding Style Comfort 1, 2 Pull the system rearward to one of the first two positions for all-day trail riding comfort. Control 3, 4, 5 Move the sy[...]

28 FEA TURES RIDER SELECT Adjusta ble Steering System 1. S top the snowmobile. 2. Press the release button and move the handlebar forward or rearward to the desired position. Cargo Rack If equipped, the maximum weight capacity for the cargo rack is 15 lbs. (7 kg). Always secure cargo before operating. Do not exceed the rack weight limit. Do not all[...]

29 FEA TURES F uel V alve The fuel valve is located under the hood. T urn the fuel valve of f when- ever the snowmobile is stored or parked. 1. T urn the valve clockwise to turn off the fuel supply . 2. T urn the valve counter-clock- wise to turn on the fuel supply . Seat Storage Compartment Open or close the stor- age compartments with the key , o[...]

30 FEA TURES Detonation Elimination T echnology (D.E.T .) The DET system prevents damage to the engine from detonation while developing the maximum power of the en gine safely . A detonation sen- sor monitors the engine and respon ds to detonation by automatically reducing the engine timing. This can result in decreased engine RPM and performance. [...]

31 FEA TURES Detonation Elimination T echnology (D.E.T .) DET T roubleshooting Use this chart to determine causes an d solutions for detonation. If none of these conditions exists and the sensor remains activated, see your Polaris dealer for diagnosis. Sensor F ail-Safe The DET includes a sensor fail-safe system to prevent the engine from damage if[...]

32 FEA TURES Instrumentation MFD Component Identification Digital Display Identification Item 1 Analog Gauge (if equipped) 2 Digital Gauge 3 CHECK ENGINE Indicat or 4 Low Oil Indicator 5 High T emp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator Item 1 RPM or Speed Altitude (if equipp ed) Service Interval 2 Electrical System V[...]

33 FEA TURES Instrumentation MFD Settings W ith the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch ( 9 ) has a MODE but- ton (top) and a SET button (bottom). Standard vs. Metric The MFD will display either stan- dard or metric units of measurement. While viewing a screen that displays measure[...]

34 FEA TURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle thro ugh the thre e MFD programs: Per- formance, Engine and History . Each program will remain in the display until another is selected. Performa nce Program While in the Performance mode, press the SET button to cycle through the settings: odometer , T rip 1, [...]

35 FEA TURES Instrumentation MFD Digital Display Programs T rip Settings Tr i p 1 a n d Tr i p 2 a r e odometers used to check fuel mileage or to keep track of distance traveled. 1. T o reset a trip odometer to zero, enter the T rip 1 or T rip 2 display . 2. Press and hold the SET button for two seconds. If the snowmobile is equipped with an electr[...]

36 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram The Engine Program auto matically displays the engine coolant tempera- ture, engine hours, electrical system voltage level and fuel level (if equipped). On machines equipped with altimeter sensor and ambient air temperature sensors, altitude and ambi ent air temperature will [...]

37 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram Altitude (if equipped) The rider can calibrate th e altimeter for current atmospheric conditions . Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. NOTE: Press and hold the MODE switch for ten seconds to switch betwee n stan- dard and metric units of measu re- m[...]

38 FEA TURES Instrumentation MFD Digital Display Programs History Program The History Program automatically di splays electrical syste m voltage level and fuel level. While in the History mode, press the SET button to view maximum vehicle speed, maximum engine rpm or the current service interval set- ting. The gauge automatically logs the maximum s[...]

39 FEA TURES Instrumentation MFD Digital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders. When the logged hours reaches the designated service interval (set by the user), the gaug e provides a re minder that service is due. "SErVCE" will flash in the odometer area and "EN[...]

40 THE PERFECT FIT F ront Suspension Adjustments Independent F ront Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from ri der to rider , depending on rider weight, vehicle speed, riding style, an d trail conditions. W e recommend starting with factory settings and[...]

41 THE PERFECT FIT F ront Suspension Adjustments Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions. Please see your Polaris de aler for assistance before attempt- ing to adjust preload. Increasing the spring preload too mu ch may adversely affect the han- dling of the snowmobile and the pe rforman[...]

42 THE PERFECT FIT F ront Suspension Adjustments Shock Compres sion Da mping (if equipped) T urn the adjustment knob to make adjustments to the compressio n damp- ing. The standard setting is 10 clicks from the full stop position. When adjusting, we recomm end that you turn the knob only one click, then test ride. Always adjust both shocks equally [...]

43 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 design s and adjustments involve a compromise, or tra[...]

44 THE PERFECT FIT Rear Suspension Adjustments Suspension Performance Tips • Rider weight usually determines th e position at which the spring pre- load should be set. However , this may vary with riding style. W ith a little experimentation, each rider can find a preferred setup. These adjustments are easy to make, involv e very little time or e[...]

45 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 the first measurement with no rider and with the re ar suspension at full extension. NOTE: The re ar bumper may need [...]

46 THE PERFECT FIT IQ Rear Suspensi on Adjustments T orsion Spring Preload T o adjust rear torsion spring preloa d, rotate the three-position cam using the engine spark p lug tool. Adjust ment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will require significantly more ef fort. Differen[...]

47 THE PERFECT FIT IQ Rear Suspensi on Adjustments Rear Shock Compression Damping (Pre mium Shocks) T urn the adjustment knob on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster slightly , then test ride. •T urn the knob clockwise (A) fo[...]

48 THE PERFECT FIT IQ Rear Suspensi on Adjustments Suspension Coupling On all Polaris snowmobile rear suspensi ons, there are two torque arms that control the mo vement of the rail beam. Pr ior to the advent of sus- pension coupling, thes e torque arms could move independently of each other . Rear suspension coupling links the movemen t of the fron[...]

49 THE PERFECT FIT IQ Rear Suspensi on Adjustments Rear T o F ront Coupling and the Rear Rear Scissor Stop (RRS S) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque ar m and limits the am ou nt of indepen- dent movement be tween the rear torque and the fron t torque arm. Adjusting the RRSS either al[...]

50 THE PERFECT FIT IQ Rear Suspensi on Adjustments W eight T ransfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scis sor stop ( RRSS). The factory setting is the best for most trail riding conditions. T o decrease weight transfer under acceleration (for improved corner-[...]

51 THE PERFECT FIT SwitchBack 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. Dif ferent 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[...]

52 THE PERFECT FIT SwitchBack Rear Suspension Adjustments Rear Shock Compression D amping T urn the adjustment knob on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster slightly , then test ride. • T urn the knob clockwis e (A) for a stif[...]

53 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 acce ssories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • V oiding of warranty • Injury [...]

54 THE PERFECT FIT Handlebar Adjustments When making handleb ar adjustments, always be sure the handlebars, brake lever and throttle lever operat e smoothly and do not contact the fuel tank, windshield o r any other part of the vehicle when t he handle- bars are turned fully to the left or right. Handlebar Angle Follow these steps to adjust handle-[...]

55 THE PERFECT FIT Handlebar Adjustments Handlebar Position If your snowmobile is equipped with the RIDER SELECT feature, adjust handlebar positio n as outlined on page 27. For models with sta- tionary steering posts, adjust ha ndlebar position as outlined below . Refer to the illustration on page 54. 1. Remove the handlebar cover . 2. Loosen the f[...]

56 THE PERFECT FIT T raction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. Use only Polaris traction prod ucts on your snowmobile. Track warran- ties are void if track damage or fa ilure results from improper or exces- sive stud installation or t he[...]

57 THE PERFECT FIT T raction Products n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmob ile and t o prevent ski wear caused by contact with roads and other bare terrain. Us e carbide skags with studded tracks to help maintain proper vehicle steering and control. See page 1 17. If your [...]

58 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on th e checklist for proper operation or condition before each use of the snowmob ile. Procedures are outlined on the ref- erenced pages. Look for a checkmark ( n ) on the refere nc ed pages to locate the pre-ride inspection items. Item See P age Drive Belt Condi tion 107, 109 Steering S[...]

59 PRE-RIDE INSPECTIONS 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 are func[...]

60 PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items fo r proper operation before starting the engine. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip than 1/2 I (1.3 cm). A smaller distance indicates low brake fluid leve l or air in the hydraulic system. Refer to the br[...]

61 PRE-RIDE INSPECTIONS Before Starting the Engine n P arking Brake Lever Lock Use the parking brake lever lock onl y when you want the machine to remain stationary; for ex ample, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reser- voir/ Cover 4. Fluid Level Indicator [...]

62 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full le ft and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstru cting the steering linkage. NOTE: If your snowmobile is equip[...]

63 PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the snowmobile pr otects the operator from moving parts as well as aiding in sound emission con trol and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always en sure that the hood straps are in good co ndition an[...]

64 PRE-RIDE INSPECTIONS Start the Engine and Check 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 st ops when the ignition switch is turned to OFF . n T ether Switch (if equipped) If your machine has a tet[...]

65 OPERA TION Starting the Engine Starting a Cold Engine Do not depress the throttle until the engine starts. 1. T urn the fuel valve on. See page 29. 2. T urn the key to the ON position. 3. Pull the engine stop switch up to the RUN position. 4. Flip the choke toggle to FULL ON. 5. If equipped with electric start, turn the key to ST AR T to crank t[...]

66 OPERA TION Starting the Engine Starting a W arm Engine 1. T urn the key to the ON position. 2. Pull the engine stop switch up to the RUN position. 3. If equipped with electric start, turn the key to ST AR T to crank the engine. Release the key to the ON position when the engine starts. 4. If not equipped with electric s tar t, grasp the starter [...]

67 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 71. Oil Recommendations This snowmobile is equipped with a variab le exhaust system (VES). Engine lubrication comes from oil ad ded to the fuel and oil injection systems. Polaris recommends the use of VES II 2 Cycle Oil for this engine. Se[...]

68 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 sup- port the rear of the snowmobile at the rear bumper . The track should be about 4 I (10 cm) off the ground. 2. S tart the engine and allow it to warm up two to three minutes. 3. Depress the thro[...]

69 OPERA TION Fu e l WAR N I NG Gasoline is highl y flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling gasoline. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or [...]

70 OPERA TION Fu e l For peak performance, Polaris recomm ends the use of 91 octane or higher fuel. Alt hough 87 octane fuel is usable, some engine p erfor- 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-[...]

71 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 67 for oi l recommendations. n Low Oil Level Maintaining the proper oil level w ill prevent system aeration and possi- ble loss[...]

72 OPERA TION Carburetion Proper carburetor adjustment is c ritical. A lean mixture (too much air , too little fuel) may result in piston bu rning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance. A lean mixture may be caused by thin gs like fuel [...]

73 OPERA TION Carburetion Jetting Guidelines Changes in altitude and temperatur e af fect air density , which is the amount of oxygen avai lable for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. The carbure tors are calibrated for an a ltitude of 0-[...]

74 OPERA TION n Engine Stop Switch Push down on the engine stop switch ( 9 ) to ground out the ig nition and stop the engine quickly . Pull the switch up to the ON 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 throttl[...]

75 OPERA TION Throttle Lever If the engine stops abruptly when the throttle lever is released: 1. T urn the ignition switch to OF F . 2. V isually inspect the throttle cable and carburetor to determine what caused the safety switch to activate. 3. T est the throttle lever by compressi ng and releasing it several times. The lever and cable must retu[...]

76 OPERA TION Emergency Stoppi ng The following chart lists methods for stopping the snowmobile in the event of an emergency . See page 74 for more information about the engine stop switch and throttle safety switch. SYSTEM WHA T IT DOES THROTTLE CONDITI ON Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Choke Floods engin[...]

77 OPERA TION Emergency Starting If the recoil starter system fails, an em ergency start strap is provided in the tool kit. 1. Open 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. S tarting at one of the tower struts, wind the strap counter- clockwise around t[...]

78 OPERA TION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine RPM is below 4000. Engaging Reverse 1. S top the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear . 3. Push the yellow reverse button on the left-hand control for one sec- ond, then release. The engine will automa[...]

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

80 MAINTENANCE Emission Control Information Any qualified repair shop or qualifie d person may maintain, replace, or repair the emission control devices 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- [...]

81 MAINTENANCE Emission Control Information Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited W arranty on page 136, 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 [...]

82 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 138. The recommended maintenance schedul e on your snowmobi[...]

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

84 MAINTENANCE P eriodic Maintenance Interval T able Item See Pag e Frequency 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 101 II II Brake Disc -- II II Parking Brake 61 II II Brake System 60, 101 I Brake Fluid 102 R FUEL MANA[...]

85 MAINTENANCE P eriodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Item See Pag e Fr eq u e nc 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 Stee[...]

86 MAINTENANCE Lubrication F ront Suspension Lubricate the steering post U-joint (with engine fog- ging oil at the intervals outlined in the maintenance charts beginning on pa ge 82. Lubricate the U-joint after seasonal storage as well as before seasonal storage. See page 122 for the part numbers of Polaris products. The front suspension does not r[...]

87 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges 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, turn th[...]

88 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil leve l at the intervals outlined in the maintenance charts beginning on page 82. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). Change the chaincase oil after the first 500 miles (800 [...]

89 MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4) 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 surfaces on the drain plug and the o[...]

90 MAINTENANCE Spark Plugs A new engine can cause temporary spar k plug fouling du e to the preser- vative added during th e assembly process. A void prolo nged idle speeds, which cause plug fouling and carbonization. Refer to your Owner's Manual Supplement for the specific spa rk plug to be used in your mach ine. Change the sp ark plugs every[...]

91 MAINTENANCE Spark Plug Condition Spark plug condition is in dicative 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 speeds. Immediately check the spark plug for correct color . NOTE: Incorrect fuel mixture can often cause a spark plug to appe [...]

92 MAINTENANCE Spark Plug Removal and Replacement 1. Remove the spark plug cap. 2. Using the special wrench provided in the tool pouch, rota te the spark plug counterclockwise to remove. 3. Reverse the procedure fo r spark plug installation. 4. T orque to 18-22 ft . lbs. (24-30 Nm). 5. Reinstall the spark plug cap. Oil Lines Inspect oil line condit[...]

93 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow , check the foam fil- ters periodically to remove any accumulation of snow . 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 F[...]

94 MAINTENANCE Carburetor The number stamped in the end of th e main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It's your dealer's responsibility to make sure the correct main jet is installed. Carburetor Adjustments The frequency at which the carburetor s are sy[...]

95 MAINTENANCE Carburetor W ater/Sediment T rap 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 10 00 miles (1600 km) and inspected for contamination. Cleaning Procedure 1. T urn the fuel valve off. [...]

96 MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water , which will provide adequate f reeze protection under most conditions. If the vehicle will be st ored or oper- ated at extremely low temperatures, greater protection may be required. Please see your Pola[...]

97 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 your mach ine after the high temperature indi- cator light has come on, driv e slowly and stop frequently to al[...]

98 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. Perform the bleeding procedure when the engine is cold. 1. Remove the pressure cap and fill the coolant bottle with pr[...]

99 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approx imately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting. 1. Open the hood and inspect the mu ffler and pipes for cracks or dam- age. 2. Check for weak o r missing retaining springs or damper/su pport grommets. 3.[...]

100 MAINTENANCE Drive Chain T ension Check drive chain tension wee kly and before each long trip. T o obtain correct chain tension: 1. Rotate the driven clutch counter- clockwise 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 (1). 3. Fi[...]

101 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect brake lever travel before each use of the snowmobile. See page 60. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing pl ate (approximately 1/16 I ). A kit is available for replacing brake pads. See your dealer . Brake Components 1. Brake Caliper 2. [...]

102 MAINTENANCE Brakes Brake Fluid The brake fluid level can be seen through a plastic sight glass in the brake reservoir . If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See pa[...]

103 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system w ill cause spongy brake lever action. Bleed the system before operating the snowmobile. During the bleeding proc edure, keep the brake handle as level as po ssi- ble. The reservoir must be in this position to minimize the possibility of air entering the sy[...]

104 MAINTENANCE Lights NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causin g a hot spot that will shorten the life of the lamp. If fingers do touch the bu lb, clean it with an alcohol- moistened towel. Headlight Bulb Removal 1. Remove the plenu m covering from the headlight assembly . 2. Lift the rubber boot [...]

105 MAINTENANCE Lights T aillight/Brakelight Replacement 600 HO IQ 1. Open the rear storage compart- ment. 2. Reach into the compart ment and locate the socket assembly above the door opening . 3. T urn the socket coun terclockwise 1/4 turn. 4. Carefully pull the socket assembly away from the taillight. 5. Install a new bulb. Reinstall the socket a[...]

106 MAINTENANCE Clutch System Periodically inspect clutch sheaves fo r damage , wear or belt residue. T o maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. Clutch Alignment Offset Clutch alignment offset i s import ant for maintaining optimum perfor- mance. See your dealer for service an d adjustments. A spe[...]

107 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 be lt for signs of excessive wear: frayed edges, missing cogs, cracks and excessiv e looseness. Replace the belt if any of these conditions exist. Se e Drive Belt T roubleshooting on page 128. F[...]

108 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 operate in th e same direction of rotation by positioning the identifica- tion numbers so that you can read them. If required, separate the sheaves as outlined in [...]

109 MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should b e 1 1/4 I (3.2 cm). Drive Belt Adjustment TEAM Clutch 1. Install the L-wrench into the op[...]

110 MAINTENANCE F a ll T une-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer . His experienced and trained service technician will keep your machine in peak oper ating condition. T rack Maintenance T rack Inspection 1. Using a hoist, safely lift and support the rear of the snow- mobile of f the ground. 2. Rot[...]

111 MAINTENANCE T rack Maintenance T rack Lubrication The slide rail needs snow for lubric ation. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear . NOTE: If excessive rail slide wear occurs due to poor snow con ditions, additional wheel kits are a[...]

112 MAINTENANCE T rack 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 ma de only after the track is warmed up and lim ber . 1. T urn the engine off. 2. Lift the rear of the machi ne and safely support it of f the ground. 3. Place t[...]

113 MAINTENANCE T rack Maintenance T rack T ension 4. Check for specified slack between th e wear surface of the track clip and the plastic slider . Refer to the Track T ension Data Chart on page 11 2 . If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the locknuts. 7. T igh ten or loosen th e track adju sting screws (4)[...]

114 MAINTENANCE T rack Maintenance n T rack Alignment Periodically check that the track is centered and runnin g evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the ma chine with the track of f the ground. 2. S tart the engine and apply a small amount of throttle unt il th[...]

115 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, ch eck all steering system fasteners and tighten if necessary . 9 9 9 9 9[...]

116 MAINTENANCE Steering System Ski Alignment W ith the handlebars in a st raight ahead position, and with vehicle 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 po int X should be 1/8 I to 1/4 I (3-6 mm) greater than the measurement at poin[...]

117 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 skags must be replaced if an y abnormal we ar or chip- ping is found. Skag Replacement 1. Raise and support the fron t of the mac[...]

118 MAINTENANCE Steering System n Rail Slide Wear Measure slide thickness at several points along the rail. Have your dealer replace the slide when it's worn down to the top of the wear limit indicator groove ( 9 ). Do not operate the snowmobile if slide thickness measures les s than 7/16 I (1.1 cm). Suspension Maintenance n Pre-Ride Suspensio[...]

119 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 122 for the part nu mbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, an d waxing the hood, chass[...]

120 MAINTENANCE Extended Storage Bearings Grease the jacks haft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a simi lar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive b elt and store in a co ol dry locati on. Do not lubricate clutch components, except the driven clutch sh aft bus[...]

121 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connecto rs. 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 maintained during summer storag e. The machine should be sup[...]

122 POL A RIS PRODUCTS Pa r t N o . Description Engine Lubrica nts 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (gal.) 2872[...]

123 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 • S EE YOUR DEALER. Driven clutch mal- function • SEE YOUR DEA[...]

124 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[...]

125 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 spa rk. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is on. • Use the choke. See page 65. • Make sure t[...]

126 TROUBLESHOOTING IQ Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper static sag (see page 45). • Change torsion spring to stif fer optional spring (see your dealer). • Revalve rear track s hock (see your dealer). Rides too stiff in rear • Check for binding[...]

127 TROUBLESHOOTING SwitchBack Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Set static sag (see page 45). Adjust torsion spring blocks or install o ptional torsion springs to achieve correct sag dimensions. • Increase shock compre ssi on damping (see page 47). Rides too stiff in rear • Check for bindi ng[...]

128 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gea r the machine down. Che ck belt deflection. Insufficient warm-up • W arm th e 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 [...]

129 WA RRANTY Service and W arranty Information Obtaining Service and Warranty Assistance Read and understand the service data an d the Polari s warranty information con - tained in this manual. Contact your Polaris dealer for replacement parts, ser- vice or warranty . Y our dealer recei ves frequent updates on changes, modifications and tip s on s[...]

130 W ARRANTY Service and W arranty Information Polaris Anti- Theft System The Polaris anti-theft system (P A TS) monito ring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft . A. In addition t o notifying th e proper law enforcemen t officials, the [...]

131 WA RRANTY 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 Polaris snowmobile against defects in material or workmanship. This warranty cove rs the parts and labor charges for r epair or replacement of defective parts t hat are cove red by this warranty . [...]

132 W ARRANTY Limitations of warranties and remedies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AN D 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 [...]

133 WA RRANTY Conditions and Exclusions In order to qualify for warranty , the product must have been prop erly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perfor m all applicable servic e bulle tins and have the consumer sign the PDI form prior to d elivery m[...]

134 W ARRANTY Polaris Second Y ear Engine Service Contract Second Y e ar Engine Service C ontr act is standard on all el igible new and unused snow- mobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promot ion. The free Second Y ear Engine Service Contract is honored by all authorized Pola ris sno[...]

135 WA RRANTY 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 SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Deale[...]

136 W ARRANTY 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 designed, bui lt and equipped so it confor ms to cu[...]

137 WA RRANTY 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 limit ed warranty excludes failures not ca used by a defect in material or workmanship. This lim- ited warranty [...]

138 MAINTENANCE L OG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will prov ide you and future owners with 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[...]

139 MAINTENANCE L OG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

140 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 53 Adjustabl e Headlights . . . . . . . . . . . 29 Adjustable Steering System . . . . . 27-28 Air Pollution . . . . . . . . . . . . . . . . . . . 5 Avalanches . . . . . . . . . . . . . . . . . . . . 13 B Bearings . . . . . . . . . . . . . . . . . . . . . 120 Before Starting the Engine. .[...]

141 INDEX I IFS Components . . . . . . . . . . . . . . . . 40 Inadequate Snow Conditions . . . . . . 18 Instrumentation . . . . . . . . . . . . . . 32-39 Intake Filters . . . . . . . . . . . . . . . . . . . 93 Intake Silencer . . . . . . . . . . . . . . . . . 17 J Jetting Guid elines . . . . . . . . . . . . . . . 73 L Lights . . . . . . . . . . . .[...]

142 INDEX S Studs . . . . . . . . . . . . . . . . . . . . . . . . 56 Survival Prep aration . . . . . . . . . . . . 10 Suspension Coupling, IQ . . . . . . . . . 48 Suspension Inspection, Pre-Ride . . 118 Suspension Maintenance . . . . . . . . 118 Suspension Performa nce Tips . . . . . 44 Suspension, Front, Lubrication . . . . 86 Suspension, Rear, Lu[...]