Polaris 600 IQ manual

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

W ARNING Read, understand, and follow all of the in structions and safety precautions in this manual and on all produ ct labels. Failure to follow the safety precautions could result in serious injury or death . W ARNING The engine exhaust from this p roduct contains chemicals known to the S tate of California to cause cancer , birth defect s or ot[...]

1 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www .polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products. ?[...]

2 POLARIS and IQ are registered trademarks of POLARIS Industries Inc. Copyright 2013 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- ancies may result betwee[...]

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

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5 INTRODUCTION Import ant Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations. Y our mode l may differ . Follow the maintenance program ou[...]

6 INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education cam- paign. W e encourage state and provincial governments across the snow- belt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation. Snowmobile clubs and other or ganiza[...]

7 INTRODUCTION V ehicle Identification Numbers Record your snowmobile’ s identificati on 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 blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced. V [...]

8 SAFETY Operator Safety The following signal words and symbol s appear througho ut this 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 safety alert symb ol ind icates a potential personal injury haza rd. DANGER A DANGER indicates a haz[...]

9 SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 75 of this manual to ensure that all critical co mponents on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before o[...]

10 SAFETY Operator Safety St ay Clear of T rack Y our snowmobile is propelled by a revolving track that must be partially exposed for proper operation. W ARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to st ay clear of the track. Never hold the snowmobi[...]

11 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar gr ips for proper throttle, brake and steering control. W ARNING[...]

12 SAFETY Operator Safety Riding App arel Helmet W earing a helmet can prevent a severe head injury . Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania[...]

13 SAFETY Operator Safety Rider Cap acity Y our snowmobile is designed for up to two riders. A decal on the console indicates that the vehicle is designed for one operator and one passenger only . W ARNING! Operating improperly with a passenger could cause loss of control and result in serious injury or death. Contro l becomes more difficult with t[...]

14 SAFETY Operator Safety Cargo Cap acity See page 32 for car go loading information. W ARNING! Overloading the cargo carrier can cause loss of con trol resulting in severe injury or death. The maximum cargo carrier cap acity is 75 lbs. (34 kg). Never exceed the cargo carrier cap acity . Disabled Operators Safe operation of this rider -active vehic[...]

15 SAFETY Operator Safety Excessive Speed W ARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather . Always be alert and pay attention to the trail ahead. If your speed is 40 MPH (16 km/h), your snowmobile is tr aveling about 60 feet (18 m) per seco[...]

16 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[...]

17 SAFETY Operator Safety A valanches Snowmobilers should always be prop erly trained and equipped before traveling in mountainous terrain: • T ake an av alanche class • 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[...]

18 SAFETY Operator Safety Ice and Snow Build-up W ARNING! Ice and snow build-up may in terfere with the steering of your snowmobile, resulting in serious injury or death. Ke ep the und erhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right s[...]

19 SAFETY Operator Safety Driving on Slippery Surfaces W ARNING! Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and us e extra caution. Driv ing on ice or hard- packed snow reduces steering and braking control, which may result in loss of control and serious injury or death. Slow down and use extra c[...]

20 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt r emoved. CAUTION! Operation of the engine with the bel t removed may result in personal injury or damage to the engine. Any servicing that requires operation without a belt must be performed by your dealer . Int ake Silencer Do not operate the engine with the intake[...]

21 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubr ication for the power slide suspension and, on liquid cooled models, coo ling for the engine, adequate snow cover is a requirement for operation of your snowmobile. NOTICE: Driving in too little snow will resu lt in excessive wear and damage to the slide rail, tr[...]

22 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 yourself with the machine and with what it will and won’t do under various conditions. Even seasoned driv- ers should spend some [...]

23 SAFETY Operator Safety Windchill/T emperature Chart s The following information is provided to help you determine when tem- peratures become dangerous for riding. WIND CHILL CHART (°F) WIND CHILL CHART (°C) Wind S peed 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 [...]

24 SAFETY Safety Decals and Locations W arning decals have been placed on t h e snowmobile for your protec- tion. Read and follow the instructions of the decals and other warnings on the snowmobile carefully . If any of the decals depicted in this manual differ from the decals on your snow mobile, always read and follow the instructions of the deca[...]

25 SAFETY Safety Decals and Locations Passenger W arning Snowmobiles designed for an operator and one passenger have a warn- ing decal on the console. For more information on operating with a pas- senger , see page 13. W ARNING This vehicle is designe d for operator and “ONE” passenger only . T rack W arning W ARNING St ay clear of tr ack. Do n[...]

26 SAFETY Safety Decals and Locations Reverse W a rning POLARIS snowmobiles equipped with standard reverse and will have this decal on the console: W ARNING Reverse operation, even at low speeds, can cause loss of control resulting in serious injury or deat h. T o avoid loss of control, always: • Look behind befo re and while backing up. • A v [...]

27 SAFETY Safety Decals and Locations Operation W arning An operation warning decal is present on the console of all POLARIS snowmobiles: W ARNING • T o avo id serious in j ury or death, read and understand all warnings and the Owner ’s Manual before oper ation. If manual is missing, con- t act a POLARIS dealer for a replacement. • This vehic[...]

28 FEA TURES 3 4 5 6 12 2 1 9 10 11 13 14 15 16 17 18 7 8 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. Windshield 7. Mountain Bar 8. Handlebar 9. Seat 10. Backrest 1 1. T aillight s 12. Cargo Carr ier 13. Rear Bumpe r 14. Snow Flap 15. T rack 16. Suspension 17. Passenger Grab Handle 18. Seat Latch 19. Fuel Filler Cap 19[...]

29 FEA TURES 2 5 6 14 7 8 12 13 3 10 9 1 4 1. Glove Box 2. MFD Display 3. Ignit ion Switch 4. Shifter 5. Recoil St arter Handle 6. Brake Lever 7. Handlebar Grip Warmer Switch 8. Thumbwarmer Switch 9. Throttle Control 10. Engine S top Switch 1 1. Electronic Reverse B utton 12. MFD Control Switch 13. Headlight Dimmer Switch 14. Parking Brake Lock 11[...]

30 FEA TURES Backrest The backrest can be adjusted for rider comfort. Whenever making adjustments, always make sure all lock levers are securely locked before operating. Tip : If an adjustment is difficult, rotate the lock levers counter-clockwise to relieve tension, then make the adj ustment. Always tighten the levers after adjusting. Height Adjus[...]

31 FEA TURES Shif ter For normal operation, place the transmission in high gear . When- ever towing or operating with a heavy load, place the transmission in low gear . See page 73. When operating in low gear , vehicle speed will be limited to protect the drive train. Glove Box The glove box is a heated dry stor - age area intended for drying wet g[...]

32 FEA TURES 12-V olt DC Outlet Use the 12-volt DC outlet to power a global positioning sensor (GPS), heated helmet shield, utility light, cell phone or other accessories. The outlet is located on the console near the ignition switch. Cargo Carrier Whenever towing or operating with a heavy load, place the transmission in low gear . See page 73. W A[...]

33 FEA TURES Fuel Resistor This snowmobile is equipped with a feature that allows the engine con- troller to select the proper operating software based on the type of fuel being used. See pages 62-63 for fuel information and recommendations. Make sur e the correct r esistor is installed for your fuel choice as instructed below . PREMIUM NON-ETHANOL[...]

34 FEA TURES Detonation Elimination T echnology (DET) The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate, flicker or flash momentarily .. Y ou may notice decreased engine RPM and performa[...]

35 FEA TURES Instrument ation MFD Component Identification Digit al Display Identification Item 1 Analog Gauge (if equippe d) 2 Digital Gauge 3 Check Engine Indicator 4 High T emp Indicator 5 Brake Indicator 6 Reverse Indicator 7 High Beam Indicator Item 1 RPM or S peed Altitude (if equipp ed) Service Interval 2 Electrical System V oltage Level 3 M[...]

36 FEA TURES Instrument ation MFD Settings The MFD control switch allows you to set the MFD display to your pref- erences. The rocker switch has a MODE button (top) and a SET but- ton (bottom). Specific instructions are outlined on the following pages. MFD settings can be made with the engine running or with the engine off. If the engine is of f, m[...]

37 FEA TURES Instrument ation MFD Settings Speedomete r /T achometer If your model is equipped wi th both analog and digital displays, the speedometer and tachometer can be viewed in either display . If the ana- log display is set to show speedometer readings, the digital screen will automatically display the tachometer (option 1). If the analog is[...]

38 FEA TURES Instrument ation MFD Digit al 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 cy cle through the program’ s screens. Performa[...]

39 FEA TURES Instrument ation MFD Digit al Display Programs Performance 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 o[...]

40 FEA TURES Instrument ation MFD Digit al Display Programs Performance Program Clock Setting (if equipped) 1. Enter the Performance Program. 2. Press and release the SET button until the clock screen is active. 3. Press and hold the SET button for five seconds. 4. When the hour starts flashing, press the SET switch once to advance on e hour . ( Pr[...]

41 FEA TURES Instrument ation MFD Digit al Display Programs Engine Program Press and release the MODE button until the engine program screen is active. The default display for this screen includes engine hours, electri- cal system voltage level, fuel level (if equipped) and either engine cool- ant temperature, air temperature (accessory) or altimet[...]

42 FEA TURES Instrument ation MFD Digit al Display Programs Engine Program Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. 1. Enter the Engine Program. Tip : Press and hold the MODE switch for te n sec- onds to switch between standard and[...]

43 FEA TURES Instrument ation MFD Digit al Display Programs History Program Press and release the MODE button until the history program screen is active. This screen will always disp lay electrical system voltage level and fuel level (if equipped). Press and release the SET button to cycle through the Maximum V ehicle Speed, Maximum Engine RPM and [...]

44 FEA TURES Instrument ation MFD Digit al Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service reminders. When the logged hours reaches the designate d service interval (set by the user), the gauge provides a reminder that service is due. “SErVCE” will flash in the odo[...]

45 FEA TURES Instrument ation MFD Digit al Display Programs History Program Service Interval Reminder T o reset the r eminder at a new interval: 1. Enter the History Program. 2. Press and release the SET button until the service interval screen is active. 3. Press and hold the SET button for five seconds, until the hours begin to flash. Immediately[...]

46 THE PERFECT FIT IQ Front Suspension Adjustment s Independent Front Suspension (IFS) Break in the suspension for approx imately 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider , depending on rider weight, vehicle speed, riding style, and trail conditions. W e recommend starting with factory set[...]

47 THE PERFECT FIT Rear Suspension Adjustment s Rider weight, car go weight, riding style, trail conditions and vehicle speed all af fect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver the best performance for a given set of conditions. However , all suspen- sion designs and adjustments involve a compro[...]

48 THE PERFECT FIT Rear Suspension Adjustment s Initial Spring Preload Setting (Sag Method) T o set up the rear suspension tors ion spring preload, measure the dis- tance between the ground and rear bumper . This is measurement X. T ake the first measurement with no rider and with the rear suspension at full extension. Tip : The rear bumper may nee[...]

49 THE PERFECT FIT Rear Suspension Adjustment s T orsion S pring Preload T o adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. This ad justment is easier to make if tension is relieved from the spring. Exercise extreme caution if you use this method of adjustment, and follow t he steps below careful[...]

50 THE PERFECT FIT Rear Suspension Adjustment s Limiter Strap Position (Ski Pressure) The following information is provided only as a guideline to be used for initial suspension set-up. Y our set-up may vary based on your desired riding style. High : Limiter strap in high position increases ski pressure Low : Limiter strap in low position decreases[...]

51 THE PERFECT FIT Rear Suspension Adjustment s Shock Compression V alving The rear track shocks for this model are gas char ged shocks. The valv- ing on the gas charged shocks is pre-set.[...]

52 THE PERFECT FIT Handlebar Adjustment s Use the following steps to adjust ha ndlebar angle at the handlebar block. 1. Remove the mount ain bar . 2. Remove the handlebar cover . 3. Using a 7/16" wrench, loosen the four nuts on the bottom of the adjuster block. T urn the handlebar to the left or right for access to the back nuts. If nec- essar[...]

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

54 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer - enced pages. Item See Page Drive Belt Condi tion 96 S teering System 56 Brake Fluid 57 Brake Lever/Parking Brake Lock 57, 58 Brake System 89 Throttle Lever 55 Throt[...]

55 PRE-RIDE INSPECTIONS Before St arting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. W ARNING! Operating the vehicle with worn, damaged, or malfunctioni ng components could result in serio[...]

56 PRE-RIDE INSPECTIONS Before St arting the Engine Hood Latches The hood of the snowmob ile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that the hood straps ar e in good condition and t[...]

57 PRE-RIDE INSPECTIONS Before St arting the Engine Brakes Always check the following items for 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" (1.3 cm). A smaller distance indicates low brake fluid level or a ir in the hydraulic system. See pages 89-[...]

58 PRE-RIDE INSPECTIONS Before St arting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmo- bile to remain stationary; for exam- ple, when parked on an incline for a period of five minutes or less. Lock Engagement T o engage the lock, squeeze the brake lever tightly and push for - ward on the lock. H[...]

59 PRE-RIDE INSPECTIONS Before St arting the Engine T rack Inspection W ARNING! Operating the snowmo bile with a d amaged track increases the possibility of track failure, which could c ause loss of control resulting in serious injury or death. Always in spect the track for dama ge before using th e vehicle. W ARNING! Use of traction products such [...]

60 PRE-RIDE INSPECTIONS Before St arting the Engine Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the follow- ing items on a weekly basis or before any long trip. Item [...]

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

62 OPERA TION Fuel Safety Gasoline is h ighly flammable and e xplosive under certain conditions. • Always exercise extreme caution w henever handling g asoline. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refuelin g. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or all[...]

63 OPERA TION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher . Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing mo r e than 10% ethanol. Never use E85 in your snowmobile) . NOTICE:[...]

64 OPERA TION Break-In Period Engine Break-In Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine. Premix the first tank of fuel as outlined below . Oil added to the fuel and oil injection systems will provide the necessary engine lubrication. Tip : [...]

65 OPERA TION Break-In Period Engine Break-In Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the fi rst three hours of use. V ary the throttle openings and vehicle spee ds to reduce friction on all close-fit- ting mac[...]

66 OPERA TION S t arting the Engine 1. T u rn the key to the ON position. NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is runni ng. 2. Pull the engine stop switch up to the RUN position. 3. T u rn the key to ST AR [...]

67 OPERA TION Rest arting an Engine If the rider stops the engine by pu shing the e ngine stop switch down, restart the engine using the normal starting procedure. If the engine fails to start using the normal procedure: 1. Push the engine stop switch down to the OFF position. 2. T u rn the key to the OFF position. 3. W ith both switches OFF , sque[...]

68 OPERA TION Oil Low Oil Indicator Light The low oil indicator light may flicke r at times due to oil movement in the bottle, but when the light comes on and remains on, add the recom- mended oil before further operation. V isually check the oil level in the bottle. The engine may be operated as long as oil is visible in the oil tank. If oil is no[...]

69 OPERA TION T rack W arm-Up A loose track or flying debris could cause serious injury or death. S tand clear of the front of the snowmobile and th e moving track. Never hold the sno wmobile up or stand behind it while warming up the track. Do not use excessive throttle dur- ing warm-up or when the track is free-hanging. Be sure the rear support i[...]

70 OPERA TION Engine St op Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly . Pull the switch up to the RUN position to allow restarting. Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or[...]

71 OPERA TION Throttle Lever W ARNING! An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly , DO NOT start the engine. If the engine speed limits at 2400 RPM when the throttle lever is released: 1. T u rn the ignit[...]

72 OPERA TION Electronic Reverse (PERC TM ) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the gearcase or trans- mission if shifting is attempted when the engine is operating above idle speed . • Shift to or from reverse only when the snowmobile is stopped and[...]

73 OPERA TION Daily St orage At the end of each ride, park the sn owmobile on a level surface and sup- port it at the rear with an appropriate track stand. The track should be suspended approximately 4" (10 cm) of f the ground. Remove the key and cover the snowmobile. To w i n g For your safety , do not attempt to use a tow hitch until you&apo[...]

74 MAINTENANCE Emission Control Information Any qualified repair shop or qualified 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 control information (ECI) label and a factory-installed emissions information [...]

75 MAINTENANCE POLARIS Recommended Maintenance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log beginning on page 131. The recommended maintenance schedul e on your snowmobile c[...]

76 MAINTENANCE Periodic Maintenance Interval T able The following chart is a guide based on average riding conditions. Y ou may need to increase frequency based on riding conditions. When inspection reveals the need for rep lacement parts, always use genuine POLARIS parts, available from your POLARIS dealer . I - Inspect (clean, adjust, tighten, lu[...]

77 MAINTENANCE Periodic Maintenance Interval T able Item See Page 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 89 II II Brake Disc -- II II Parking Brakes 58 II II Brake System 57, 89 I Brake Fluid 57 I FUEL MANAGEME[...]

78 MAINTENANCE Periodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessar y) C - Clean R - Replace L - Lubricate Item See Page Frequency 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 S teering [...]

79 MAINTENANCE Lubrication Gearcase Oil Level Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 75. Change the gearcase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally . T o check the oil level, place the snowmobile on a level surface. The oil level should be bet[...]

80 MAINTENANCE Lubrication Throttle Cable Lubricate the throttle cable lightly with grease or oil. W ith the engine off , turn the han- dlebars to the left and lubri- cate liberally as shown. Front Suspension The front suspension and steering components do not require lubrica- tion. Coupler Lubrication Using a needle-point grease gun, grease the dr[...]

81 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 76 and before seasonal storage. When operating in heavy , wet snow conditions, lubricate every 500 miles (800 km). Lack of lubrication will adversely affect yo[...]

82 MAINTENANCE Spar k P l u g s A new engine can cause temporary spar k plug fouling due to the preser - vative added during the assembly process. A void prolonged idle speeds, which cause plug fouling and carbonization. NOTICE: Using non-recommended spark plugs can result in serious engine damage. A spark plug with a heat range too high will alway[...]

83 MAINTENANCE Spar k P l u g s Normal Sp ark Plug The normal insulator tip is gray , tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. Tip : The tip should not be white. A whi te insulator tip indicates overheati ng, ca[...]

84 MAINTENANCE Int ake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow , check the foam filters periodically to remove any accumulation of snow . NOTICE: Operating the snowmo bile with the intake filters removed may cause intake icing. The result wi ll be poor fuel economy or intake m[...]

85 MAINTENANCE Oil Lines Inspect oil line condition every 1000 miles (1600 km). Oil Filter The oil filter is located at the side of the oil tank. Have your dealer change the oil filter and bleed the system annually or every 1000 miles (1600 km). Have your dealer inspect the return check valve as well. Tip : The direction of the arro ws indicates th[...]

86 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water . This mixture provides protection against freezing. Contact your dealer if greater protection is required. Use POLARIS Antifreeze 60/40 Premix. POLARIS Antifreeze is already premixed and ready to use. Do not dilute wit[...]

87 MAINTENANCE Cooling System Coolant High T emperature 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 machine after the high temperature indi- cator light has come on, drive slowly and stop frequently to allow[...]

88 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! S team and hot liquids will cause burn s to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly . If the pressure cap needs replacement, contac[...]

89 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 57. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate, approximately 1/16" (1.5 mm). A kit is avail- able for replacing brake pads. See your dealer . W ARNING! Brake failure[...]

90 MAINTENANCE Brakes Brake Fluid After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopi c, meaning it ra pidly absorbs moisture from the air . The moisture causes the boiling temperature o f the brake fluid to drop, which can lead to early brake fade and the possibil[...]

91 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. W ARNING! Operating the vehicle wi th a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious in jury or death. Never operate[...]

92 MAINTENANCE Light s Removing Halogen Bulbs Tip : Do not touch a halogen bulb with bare fingers. Oil from skin leaves a resi- due, causing a hot spot that will shorten the life of the lamp. If finge rs do touch the bulb, clean it with an alcohol-moistened towel. 1. Remove the plenum cov- ering from the headlight assembly . Lift the rubber boot to[...]

93 MAINTENANCE Light s Inst allin g Halogen Bulbs 1. Hold the bulb by its metal base and install it into the wire harness. 2. Insert the bulb into the housing. 3. Connect the spring to the housing. 4. Carefully flip the spring back into the housing, placing it around the wire harness. 5. Reinstall the plenum covering on the headlight assembly . 6. [...]

94 MAINTENANCE Electrical System RELA Y LABEL FUSE LABEL ITEM POW ERED ST ART SOLENOID RELA Y Ground side of start solenoid CHASSIS RELA Y SP ARE 20A None ACCESSOR Y EMERGENCY SP ARE 30A Accessory plugs CHASSIS 30A High beams Low beams Handwarmers Thumbwarmer Passenger handwarme rs Work light T ail lamp Brake l amp Alternator coils EFI RELA Y EX. S[...]

95 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. W ARNING! If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately . Do not operate[...]

96 MAINTENANCE Clutch System 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 excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt T roubleshooting on page 121. For imp[...]

97 MAINTENANCE Clutch System Drive Belt Adjustment 1. Install the L-wrench into the open threaded hole in the outer sheave of the clutch (see page 98). T urn the wrench clockwise slightly to remove pressure from the sheaves. 2. Loosen the 7/16-inch jam nut. 3. Using a 1/8-inch Allen wrench, aturn the set screw inward (clock- wise) to increase the d[...]

98 MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the dri ve belt after operati ng in reverse. The snowmobile must be stop ped after forward moti on to prevent damage to components during belt removal. Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure forward engagement before attempting to remove t[...]

99 MAINTENANCE Clutch System Drive Belt Inst allation 1. Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer circumference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the break-in period. Adjust the belt ride-out after the br[...]

100 MAINTENANCE T rack Replacement When replacing the track, always install a track having the lug size rec- ommended for your model. See your POLARIS dealer . NOTICE: Installing tracks with larger lugs on machines equipped with coolers will result in d amage to the cooler or tunnel. Always install a trac k having the lug size recommended for your [...]

101 MAINTENANCE T rack Lubrication W ARNING! Operating with insufficient lubrication betwe en the rail slide and track guide clips can cause track failure, loss of vehicle control and lo ss of braking ability , which can result in se rious inj ury or death. Avoid operating for extended periods on ice and other surfaces that have little or no snow f[...]

102 MAINTENANCE T rack T ension W ARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving part s. Never perform track measur ement or adjustme nts with the engine running. T rack adjustment is critical for proper handling. Always maintain cor- rect te[...]

103 MAINTENANCE T rack T ension 4. Check for specified slack between the wear surface of the track clip and the plastic rail sl ide. If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7. T ighten or loosen the track adjusting sc rews as necessary to provide equal adjustment on both sides of the track. 8. Re[...]

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

105 MAINTENANCE S teering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride. T ighten any loose fasteners. X X X X X[...]

106 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment o r adjustment ma y cause loss of steering control, resulting in se rious injury or d eath. Do not attempt to change the ski alignment or camber adjustment. See your POLARIS dealer . 1. Place the handlebars in a straight-ahead position. 2. W ith only vehicle weight comp[...]

107 MAINTENANCE S teering System Ski Skags W ARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing seri ous injury or death. See your dealer's studding chart fo r recommended skags. If you install longer or more aggressi ve carbide skags than the original equipment, it may also be ne cessary[...]

108 MAINTENANCE Battery W ARNING! Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death . Wh en removin g the battery , always disconnect the negative (black) ca ble first. When reinstalling the battery , always connect the negative (black) cable last. Battery Removal 1. Release the seat [...]

109 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rechar ge as needed to maintain a full charge. Tip : Battery [...]

110 MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully . 1. Check the battery voltage with a voltmeter or multimeter . A fully charged battery will register 12.8 V or higher . 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 or greater . T[...]

111 MAINTENANCE Matte Clear Coat Cleaning (if equipped) Matte finish products are prone to trapping dirt, oils and other contaminants. POLARIS Industries recommends cleaning with warm water and a mild dish deter gent. Use a soft sponge to gently rub the surface and rinse with clean warm water . For stubborn stains such as grease or oil use a citrus[...]

112 MAINTENANCE Extended Storage Battery Maintenance Remove the battery and recharge it as outlined on page 11 0. Store the battery in a cool, dry place. Controls and Linkage Lubricate all bushings and cables at the intervals outlined in the Periodic Maintenance T able beginning on page 76. Bearings Grease the jackshaft and drive shaft clutch side [...]

113 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wi re and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts. T rack and Suspension Moderate track tension should be maintained during summer storage. The snowmobile should be sup[...]

114 SPECIFICA TIONS Cap acities and Dimensions Body Style IQ Rider Capacity 2 Coolant Capacity 9.8 qts. (9.3 l) Fuel Capacity 14.3 gal. (54.1 l) Oil Capacity 3.6 qts. (3.4 l) Gearcase Oil Capacity 20 oz. (591.5 ml) Length 138 in. (351 cm) W idth 48.75 in. (124 cm) Height 55 in. (139.7 cm) Brake T ype L/C Hydraulic Drive Clutch Center Distance 12 in[...]

115 SPECIFICA TIONS Clutching Chart AL TIT UDE Meters (Feet) Drive Clutch Shift W eight Drive Clutch Spr i ng Driv en Clutch Spr i ng Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory sett ings. 0-600 (0-2000) 11 - 6 4 (1322604) Dark Blue/White (70417 81) 140/200 P2 T ab (70434 95) 40/38-.45 P2N (5137157) 19:41 Borg/Warner 66P 60[...]

116 POLARIS PRODUCTS Part No. Description Engine L ubricant s 2870791 Fogging Oil (12 oz. Aerosol) 2875035 Premium Blue 2-Cycle Oil (qt./.95 l) (break-in only) 2875036 Premium Blue 2-Cycle Oil (gal./3.8 l) (break-in only) 2877882 VES 2-Cycle Oil (qt./.95 l) 2877953 VES 2-Cycle Engine Oil (2 qt./1.9 l) 2877883 VES 2-Cycle Engine Oil (gal./3.8 l) 287[...]

117 TROUBLESHOOTING Engine T roubleshooting Unless you have experience and training 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 malfunction • SEE YOUR DEALER.[...]

118 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Noise in drive system Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ gearcase, jackshaft, or front drive shaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed. Drive chain loose • Inspect and adjust (or replace).[...]

119 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. • Make sure the fuel tank contains fuel. • [...]

120 TROUBLESHOOTING Suspension T roubleshooting Problem Solution Rear suspension bottoms too easily • Set static sag (see page 48). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. Rides too stiff in rear • Check for binding suspension components and grease all pivot points. • Set static sag [...]

121 TROUBLESHOOTING Drive Belt Wear/Burn Cause Solution Driving at low RPM Drive at higher RPM. Gear the machine down. 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 wea the r and warm it up. Break machine loose from the snow . T owing at low RPM Do not tow[...]

122 W ARRANTY Service And W a rranty Information Obt aining Service and Warranty Assist ance Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty . Y our dealer receives frequent updates on changes, modifications and tips on snowmob[...]

123 W ARRANTY Service And W a rranty Information POLARIS Anti-Thef t System The POLARIS anti-theft system (P A TS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. POLARIS snowmobile owner reports theft. A. In addition to notifying the proper law enforcemen t officials, the own[...]

124 W ARRANTY Limited W arranty POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED W ARRANTY on all components of the POLARIS snowmobile against defects in material or workmanship. W arranty period will vary regionally . This warranty covers the parts and labor char ges for repair or replacement of defective parts th[...]

125 W ARRANTY Limit ations of warranties and remedies ALL IMPLIED W ARRANTIES (INCLU DING 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[...]

126 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 applic able). Failure of any dealer to perform the required vehi- cle Pre-Delivery Inspection, perform all ap plicable service bulletins and have the con- sumer sign the PDI form prior to delivery [...]

127 W ARRANTY Exported V ehicles EXCEPT 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. Dealers [...]

128 W ARRANTY How to Get Service If Pur chased From A Private Party: If you purchase a POLARIS product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty c overage will be denied. Y ou must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in you[...]

129 W ARRANTY U.S.A. EP A Emissions Limited W arranty This emissions limi ted warranty is in addition to the POLARIS standard limited war - ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certi fied vehicle is designed, built and equi pped so it conforms with applicable U.S. Environm[...]

130 W ARRANTY U.S.A. EP A Emissions Limited W arranty The exclusive remedy for breach of this limited warrant y shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRAN TY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF THIS[...]

131 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners wit h an accurate log of maintenance and se rvices performed on the snowmobile. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 1500 mi.[...]

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

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

134 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 53 Air Polluti on . . . . . . . . . . . . . . . . . . . 6 Apparel . . . . . . . . . . . . . . . . . . . . . . 12 Avalanches . . . . . . . . . . . . . . . . . . . . 17 B Backrest . . . . . . . . . . . . . . . . . . . . . . 30 Battery . . . . . . . . . . . . . . . . . . 108-110 Charging . [...]

135 INDEX G Gauge Cleaning. . . . . . . . . . . . . . . . . 45 Gearcase Oil Level . . . . . . . . . . . . . . 79 Glove Box . . . . . . . . . . . . . . . . . . . . . 31 H Handlebar Adjustments. . . . . . . . . . . 52 Headlight Adjusting . . . . . . . . . . . . . 30 Helmet . . . . . . . . . . . . . . . . . . . . . . . . 12 High Temperature Indicator [...]

136 INDEX S Specifications. . . . . . . . . . . . . . 114-115 Speed . . . . . . . . . . . . . . . . . . . . . . . . 15 Spring Preload, IQ . . . . . . . . . . . . . . 48 Starting the Eng ine . . . . . . . . . . . . . 66 Starting the Engine, Resta rting . . . . 67 Steering Inspec tion . . . . . . . . . . . . 105 Steering System . . . . . . . . . 56, [...]

For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polaris.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9924294 Rev 01 Printed in USA PMS 419 *9924294 *[...]