Polaris 600 IQ LXT manual

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

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 The following 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 84 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 Driving 1-Up - Some POLARIS snowmobiles are designed for a single rider only . A decal on the console of these models indicates single rider operation. Driving 2-Up - Some POLARIS snowmobiles are designed for up to two riders. A decal on the hood of these models indicates that the vehi- cle is designed for [...]

14 SAFETY Operator Safety Disabled Operators Safe operation of this rider -active vehicle requires good judgement and physical skills. W ARNING! Operators with cognitive or physical disabilities have an increased risk of loss of control, wh ich could result in serious injury or death. Do not allow disabled persons to operate this vehicle. Cargo Ove[...]

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 observe all state and lo cal laws governing snowmobile opera- tion and speed limits. Always be alert and pay attention to the trail ahead. If[...]

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 you r 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 [...]

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 braki ng control, which may result in loss of control and serious injury or death. Slow down and use extra [...]

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

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 warning decal on the left console. For more information on operating with a passenger , see page 13. W ARNING This vehi cle is designed fo r operator and “ONE” passenger only . T rack W arning W ARNING St ay clear of track. Do [...]

26 SAFETY Safety Decals and Locations Reverse W a rning POLARIS snowmobiles equipped with electric 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: • T o avoid serious injury or death, read and understand all warnings and the Owner ’s Manual before ope ration. If manual is missing, contact a POLARIS dealer for a replacement. • This vehicle is capable o[...]

28 FEA TURES 1. Nosepan 2. Skis 3. Front Bumper (do not use for pulling or dragging the snowmobile) 4. Hood 5. Headlight 6. Windshield 7. Mirrors 8. Operator Seat 9. Passenger Grab Handle 10. Passenger Seat 1 1. Backrest 12. Cargo Ba g 13. Grab Handle Heater Switch 14. T aillights 15. Rear Bumper 16. Snow Flap 17. T r ack 18. Passenger Footrest 19.[...]

29 FEA TURES 9 8 11 12 7 2 3 4 5 6 15 1 13 14 1. MFD Display 2. Handlebar Grip W armer Switch 3. Thumbwarme r Switch 4. Electronic Reverse Button 5. MFD Control 6. Headlight Dimmer Switch 7. Parking Brake Lock 8. Brake Lever 9. Ignition Switch 10. Heated Windsh ield Power Plug 1 1. Engine S top Sw itch 12. Throttle Control 13. Hood Hold Down S trap[...]

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 to relieve tension, then make the adjustment. Height Adjustment 1. Lift the upper lock levers (1) on both backrest suppo[...]

31 FEA TURES Adjust able Headlight s Move the adjuster to the left to lower the headlight beam. Move the adjuster to the right to raise the headlight beam. Radiator Comp artment Access Panel The access panel is provided for cleaning debris from the radiator . Cargo Bag The car go bag is secured to the rear of the tunnel with straps. The cargo bag a[...]

32 FEA TURES Passenger Grab Handle On some models the position of the passenger grab handles can be adjusted for rider preference. 1. Unscrew and remove the knob assemblies that secure the grab han- dles. 2. Reposition the grab handles to one of the three available positions on the grab handle tube between the operator seat and the passenger seat. [...]

33 FEA TURES RIDER SELECT Adjust able Steering System The RIDER SELECT adjustable steering system (if equipped) allows you to adjust the handlebar position to fit your style of riding. Some models have five (5) adjustment positions. Other models have seven (7) positions. W ARNING! If your snowmobile has five adjustment positions, do not remove the [...]

34 FEA TURES RIDER SELECT Adjust able Steering System W ARNING! Attempting to adjust the handle bar position while th e snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system. 1. Stop the snowmobile. 2. Press the release button and move the handleb[...]

35 FEA TURES Detonation Elimination T echnology (DET) The DET system prevents damage to the engine from detonation by automatically reducing the engine timing and adding fuel whenever the sensors detect detonation. Y ou may notice decreased engine RPM and performance when DET is activated, but in most cases DET activation is temporary , and the tim[...]

36 FEA TURES Instrument ation MFD Component Identification Digit al Display Identification Item 1 Analog (i f equipped) 2 Digital Gauge 3 Check Engine Indicator 4 Low Oil Indicator 5 High T emp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator Item 1 RPM or S peed Altitude (if equipp ed) Service Interval 2 Electrical System V ol[...]

37 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. St andard vs. Metric The MFD will display either stan- dard or metric units of measurement. While[...]

38 FEA TURES Instrument ation MFD Settings Speedomete r /T achometer The speedometer and tachometer can be viewed in either the analog or the digital display . If the analog display is set to show speedometer readings, the digital screen will automatically display the tachomet er (option 1). If the analog is set to show the tachometer , the digital[...]

39 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[...]

40 FEA TURES Instrument ation MFD Digit al Display Programs T rip Settings T rip 1 and T rip 2 are odometers used to check fuel mileage or to keep track of distance traveled. Both odometers can be reset to zero. 1. Enter the Performance Program. 2. Press and release the SET button until the desired trip screen is active. 3. Press and hold the SET b[...]

41 FEA TURES Instrument ation MFD Digit al Display Programs Performance Program T rip Settings If the snowmobile is equipped with an electronic fuel gauge, T rip F automati- cally displays when the fuel level is low . The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1/8th tank. The T rip F odometer recor[...]

42 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[...]

43 FEA TURES Instrument ation MFD Digit al Display Programs Engine Program The Engine Program automatically 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 ambient air temperature will d[...]

44 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[...]

45 FEA TURES Instrument ation MFD Digit al Display Programs History Program The History Program automatically displays electrical system voltage level and fuel level (if equipped). While in the History mode, press the SET button to view maximum vehicle speed, ma ximum engine rpm or the current servic e interval set- ting. The gauge automatically lo[...]

46 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 t[...]

47 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 fiv e seconds, until the hours begin to flash. Immediatel[...]

48 FEA TURES Instrument ation MFD Battery Replacement Models equipped with the clock feature have a battery to power the clock. If the clock function of the MFD isn't working properly , replace the battery . Replace- ment batteries are available from your dealer . 1. Remove the plenum from the under- side of the hood. 2. Locate the black batte[...]

49 FEA TURES Instrument ation MFD Battery Replacement 5. Using needle-nose pliers, grasp the battery and rotate it so the lead- ing edge of the battery is raised away from the battery holder . Pull the battery out gently . Tip : The battery will not come out of the holder unless the leading edge of the battery is raised. Hold the battery compartmen[...]

50 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[...]

51 THE PERFECT FIT IQ Front Suspension Adjustment s Front Shock S pring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pres- sure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. T o change front shock sprin[...]

52 THE PERFECT FIT IQ Front Suspension Adjustment s Shock V alving The shocks can be revalved if spring preload alone isn't sufficient and further adjustment is desired to control suspension stif fness. W ARNING! Changing shock valving requires speci al to ols and a sound knowledge of mechanical theory , to ol use, and sho p procedures to perf[...]

53 THE PERFECT FIT Rear Suspension Adjustment s Rider 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 excellent performance for a given set of conditions. However , all sus- pension designs and adjustment s involve a co mp romise, or t[...]

54 THE PERFECT FIT IQ Rear Suspension Adjustment s 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 rear suspension at full extension. Tip : The rear bumper may nee[...]

55 THE PERFECT FIT IQ 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. Adjustment 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. Different [...]

56 THE PERFECT FIT IQ Rear Suspension Adjustment s Limiter Strap Position (Ski Pressure) Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter straps. T ighten the straps to increase ski pressur[...]

57 THE PERFECT FIT IQ Rear Suspension Adjustment s Suspension Coupling On all POLARIS snowmobile rear su spensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move indepe ndently of each other . Rea r suspension coupling links the movement of the front an[...]

58 THE PERFECT FIT IQ Rear Suspension Adjustment s Rear T o Front Coupling and the Rear Rear Scissor S top (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen- dent movement between the rea r torque and the front torque arm. Adjusting the RRSS either allows [...]

59 THE PERFECT FIT IQ Rear Suspension Adjustment s Weight T ransfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trail riding conditions. T o decrease weight transfer under acceleration (for improved corner - i[...]

60 THE PERFECT FIT Handlebar Adjustment s Use the RIDER SELECT feature to adjust handlebar position. See page 33. Use the following steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts. 2. Using a 7/16" wrench, loosen the four nuts on the bottom of the a[...]

61 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 snowmo- bile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • V oiding of warranty • Injury [...]

62 THE PERFECT FIT T raction Product s Stu d s Before equipping your snowmobile wi th traction products, be aware of the laws in your area pertaining to the use of traction products. Use only POLARIS traction products on your snowmobile. Track war - ranties are void if track damage or failure results from improper or excessive stud installation or [...]

63 THE PERFECT FIT T raction Product s Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and t o prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle s teering and control. See page 1 15. If your sn[...]

64 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 105 S teering System 66 Recoil Rope 65 Parking Brake Lock/Brake Lever/Brake System 67, 68, 100 Throttle Lever 65 Th[...]

65 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[...]

66 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[...]

67 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. Refer to the [...]

68 PRE-RIDE INSPECTIONS Before St arting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reservoir/Cover 4. Fluid Level Indicator Lock[...]

69 PRE-RIDE INSPECTIONS Before St arting the Engine T rack Inspection W ARNING! Operating the snowmo bile with a damage d 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 [...]

70 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 [...]

71 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[...]

72 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 : [...]

73 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 a ry the throttle openings and vehicle spee ds to reduce friction on all close-fit- ting ma[...]

74 OPERA TION Slide Rail and T rack Cooling NOTICE: Inadequate cooling and lubrica tion will lead to overheating of th e slide rail and track, resulting in p remature wear and fa ilure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfac es. Avoid operating on ice, hard-packe[...]

75 OPERA TION Fuel Safety Gasoline is highl y flammable and explosive 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 refueling. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or allow[...]

76 OPERA TION Fuel For peak performance, POLARIS recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor- mance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containi ng mor e than 10% ethanol (including E85) . NOTICE: Operating with obstructed fuel s[...]

77 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. See page 72 for oil recommenda- tions. V isually check the oil level in the bottle. The engine may be operated as long as oil i[...]

78 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[...]

79 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 stops abruptly when the throttle lever is released: 1. T urn the ignition switch [...]

80 OPERA TION Electronic Reverse (PERC) Electronic reverse will activate only if the engine RPM is below 4000 . W ARNING! Improper reverse operati on, even at low speeds, may cause loss of control, resulting in serious i njury or death. Damage will occur to th e gearcase or transmission if shifting is attempted when the engine is operating above id[...]

81 OPERA TION Electronic Reverse (PERC) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button for one second and release. The light on the instrument panel will shut of f. 3. Apply the throttle slowly to make sure the transmission is in for - ward. Emergency S t opping The following chart lists me[...]

82 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 Do not use the front bumper to pu ll or drag the snowmobile. The [...]

83 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 con- trol information (ECI) label and a factory-installed emissions informa- t[...]

84 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 135. The recommended maintenance sche dule on your snowmobile c[...]

85 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[...]

86 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 100 II II Brake Disc -- II II Parking Brakes 68 II II Brake System 67, 100 I Brake Fluid 101 I FUEL MANAG[...]

87 MAINTENANCE Periodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Item See Page Frequency 150 mi. (240 km) 5 00 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 [...]

88 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 85 and before seasonal storage. When operating in heavy , wet snow conditions, lubricate every 500 miles (800 km). Lack of lubrication will adversely affect yo[...]

89 MAINTENANCE Lubrication Driveshaf t 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 t[...]

90 MAINTENANCE Chaincase Oil Check the chaincase oil level at the intervals outlined in the Periodic Main- tenance T able beginning on page 85. 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 chain- case oil after the first 500 miles (800 km[...]

91 MAINTENANCE 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. The sealing surfaces on the drain plug and the oil tank should be c[...]

92 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[...]

93 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[...]

94 MAINTENANCE Int ake Filters The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow , check the top of the foam filter periodically to remove any accumulation of snow . Fuel Injectors All fuel injector service must be performed by an authorized POLARIS dealer . Do not attempt to clean or service t[...]

95 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). Tip : The direction of the arrows in dicates the direction of flow through the fil- ter . Exhaust System[...]

96 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[...]

97 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[...]

98 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[...]

99 MAINTENANCE Drive Chain T ension Check drive chain tension weekly 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. Fing[...]

100 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 67. 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 failur[...]

101 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 possibi[...]

102 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 operat[...]

103 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 cover- ing from the headlight assembly . 2. Lift the rubber boo[...]

104 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 immediatel y . Do not opera[...]

105 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 125. For im[...]

106 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. 1. Stop the engine after operat- ing in a forward motion. 2. T urn the ignition key off. W ait for the engine to com[...]

107 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 cir - cumference of the driv en clutch sheaves. The belt will seat itself in the driven clutch during the break- in period. Adjust the belt ride-out after [...]

108 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 [...]

109 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[...]

110 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[...]

111 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 screws as necessary to provide equal adjustment on both sides of the track. 8. Rep[...]

112 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 the rear of the snowmobile with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly at[...]

113 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[...]

114 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment o r adjustment may cau se 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 handleba rs in a straight-a head position. 2. W ith only vehicle weight co[...]

115 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[...]

116 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 components. See page 120 for the part numbers of POLARIS products. Cleaning and Preservation Proper storage starts with cleanin g, washing, and waxing the hood, chassis, [...]

117 MAINTENANCE Extended Storage Engine Protection Proper preparation of the engine and fuel system is vital to the preven- tion of rust and corrosion on precis ion engine parts during storage. Whenever the machine is stored for a period of more than 60 days, the engine must be fogged with fogging oil. Follow the engine fogging instructions provide[...]

118 SPECIFICA TIONS Cap acities and Dimensions Body Style IQ Rider Capacity 2 Coolant Capacity 7 qts. (6.6 l) Fuel Capacity 1 1.4 gal. (43.2 l) Oil Capacity 3.4 qts. (3.2 l) Gearcase Oil Capacity 9 oz. (266.2 ml) Length 127 in. (323 cm) W idth 47.25 in. (120 cm) Height 52 in. (132 cm) Brake T ype Hayes Phantom DOT 4 Drive Clutch Center Distance 1 1[...]

119 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) 10-64 (13215 85) Blac k/Green (7042083) 120/210 P2 T ab (70435 12) 42S P2 (5136402) 22:43 78P 600-1200 (2000-4000) 10-62 [...]

120 POLARIS PRODUCTS Part No. Descripti on 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) 2[...]

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

122 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Noise in drive sys- tem Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, 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 replac[...]

123 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 t he fuel tank co ntains fuel. ?[...]

124 TROUBLESHOOTING IQ Comfort Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper static sag (see page 54). • Change torsion spring to stif fer optional spring (see your dealer). • Rotate RRSS to higher position (see pag e 59). Rides too stiff in rear • Check f[...]

125 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 weather and warm it up. Break machine loose from the snow . T owing at low RPM Do not tow i[...]

126 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 infor - mation 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 snow[...]

127 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 enforcement officials, the owne[...]

128 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[...]

129 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[...]

130 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 [...]

131 W ARRANTY Conditions and Exclusions W arranty applies to the product only and does not allow for coverage of personal loss. Some items are considered “consumable,” meaning they are considered part of normal maintenance or part of completing an effective repair . The following items are excluded from warranty coverage in the event of a warra[...]

132 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 m[...]

133 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[...]

134 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 T O ANY PERSON FOR BREACH OF THI[...]

135 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.[...]

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

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

138 INDEX A Access Panel, Ra diator . . . . . . . . . . 31 Accessories . . . . . . . . . . . . . . . . . . . 61 Adjustable Steering System . . . . . 33-34 Apparel . . . . . . . . . . . . . . . . . . . . . . 12 Avalanches . . . . . . . . . . . . . . . . . . . . 17 B Backrest . . . . . . . . . . . . . . . . . . . . . . 30 Battery Replacem ent , MFD .[...]

139 INDEX F Fuel Filter . . . . . . . . . . . . . . . . . . . . . 94 Fuel Injector s . . . . . . . . . . . . . . . . . . 94 Fuel Lines . . . . . . . . . . . . . . . . . . . . . 94 Fuel Premi x (In iti al Fill) . . . . . . . . . . 72 Fuel Pump . . . . . . . . . . . . . . . . . . . . . 94 Fuel Safety . . . . . . . . . . . . . . . . . . . . 75 Fuel Sy[...]

140 INDEX S Snow Build-up . . . . . . . . . . . . . . . . . 18 Snow Conditions . . . . . . . . . . . . . . . 21 Spark Plugs . . . . . . . . . . . . . . . . . 92-93 Specifications. . . . . . . . . . . . . . 118-119 Speed . . . . . . . . . . . . . . . . . . . . . . . . 15 Spring Preload, IQ . . . . . . . . . . . . . . 54 Steering Inspec tion . . . . [...]

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. 9924222 Rev 01 Printed in USA PMS 419 *9924222 *[...]