Polaris 600 IQ Touring manual

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P antone 426C For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922288 Rev 01 Printed in USA[...]

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

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

2 POLARIS and POLARIS TH E W A Y OU T are registere d trademarks of Pola ris Indus- tries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design [...]

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

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

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

7 INTRODUCTION V ehicle Identification Numbers Record your snowmobile’ s identific ation numb ers and key number in the spaces provided. Remove the spare key and store it in a safe place. Y our key can b e 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. [...]

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

9 SAFETY Operator Safety Follow the recommended mainte nance program outlin ed beginning on page 84 of this manual to ensure that all critical co mponents on the snowmobile are thoroughl y inspected by your dealer at specific mileage intervals. Driving a snowmobile requires your full atten tion. DO NOT drink alcohol or use drugs or medications befo[...]

10 SAFETY Operator Safety St ay Clear of T rack Y our snowmobile is p ropelled by a revo lving 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 stay clear of the track. Never hold the snowmob[...]

11 SAFETY Operator Safety Riding Position Operating a snowmobile requires sk ill and balance for proper control. Rider positions may vary with expe rience; but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for prop er throttle, brake and steering control. W ARNI[...]

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

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 ar e designed for up to two riders. A decal on the hood of these models indicates that the vehicle is designed for o[...]

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

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 drivin g at night or in inclement wea ther . Always observe all state an d local laws governing snowmobile op era- tion and speed limits. Al ways be alert and pay attenti on to the trail ah[...]

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 avalan che 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 snowm[...]

18 SAFETY Operator Safety Ice and Snow Build-up W ARNING! Ice and snow bu ild-up may interf ere with the steering of your snowmobile, resulting in serious injury or death. Ke ep t he underhood area free of snow and ice. Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full left and right[...]

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

20 SAFETY Operator Safety Drive Belt Do not operate the engine wi th the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer . 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 filter[...]

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

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

23 SAFETY Operator Safety Windchill/T emperature Charts The following informatio n is provided to help you d etermine when tem- peratures become da ngerous for riding. 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 empera[...]

24 SAFETY Safety Decals and Locations W arning decals have been placed o n the snowmobile for your protec- tion. Read and follow the instructions of the deca ls and other warnings on the snowmobile carefully . If any of the decals depicted in this 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 informat ion on operating with a passenger , see page 13. W ARNING This vehi cle is de signed for 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 arning Polaris snowmobiles equipped with el ectric reverse and will have this decal on th e console: W ARNING Reverse operation, even at low speeds, can cause lo ss of control resulting in serious injury or death. T o avoid loss of control, always: • Look behind before and while back ing up. • A v[...]

27 SAFETY Safety Decals and Locations Operation W arning An operation warning decal is pres ent 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 operation. 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 drag ging the snowmobile) 4. Hood 5. Headlight 6. Windshield 7. Operator Seat 8. Passenger Seat 9. Backrest 10. Passenger Grab Han dle 1 1. Cargo Bag 12. Grab Ha ndle Heater Switch 13. T aillights 14. Rear Bumper 15. Snow Flap 16. T rack 17. Suspension 3 4 5 6 2 1 7 8 9 12 1[...]

29 FEA TURES 1. MFD Display 2. Mirrors 3. Rider Select t 4. Fuel Filler Cap 5. Handlebar 6. Hood Hold Down St r a p s 7. Handlebar Grip Warmer Switch 8. Thumbwarmer Switc h 9. Electronic Rever se Button 10. MFD Co ntrol 1 1. Headlight Dimmer Switch 12. Parking Br ake Lock 13. Brake Lever 14. Engine S top Switch 15. Throttle Co ntrol 16. Ignition Sw[...]

30 FEA TURES Backrest The backrest is adjustable for either operator or passenger use. 1. Loosen the upper adjustment knobs to raise or lower the backrest. 2. Loosen the lower adjustment knobs to move the backrest for- ward for operator use or rear- ward for passenger use. 3. Always tighten the knobs securely after adjusting. Adjust able Headlight [...]

31 FEA TURES Cargo Bag The cargo bag is secured to the rear of the tunnel with straps. The cargo bag and the passenger seat are removable to provide open storag e for transporti ng larger items. The maximum weight capacity for the cargo area is 30 lbs. (14 kg). Always s ecure cargo before operating. Do not exceed the weight limit. Do not allow a pa[...]

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

33 FEA TURES RIDER SELECT Adjust able S teering 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 S teering System W ARNING! Attempting to adj ust the handlebar positi on while the snowmo bile 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. S top the snowmobile. 2. Press the release button and move the hand[...]

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

36 FEA TURES Instrument ation MFD Component Identification Digit al Display Identification Item 1 Analog (if equipp ed) 2 Digital Gauge 3 CHECK ENGINE Indicator (carb models) 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 Electric[...]

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). Specif ic instructions are outlined on the following pages. St andard vs. Metric The MFD will display either stan- dard or metric units of measurement. Whil[...]

38 FEA TURES Instrument ation MFD Settings Spe edometer/T achometer The speedometer and tachometer can be view ed in either the analog or the digital display . If the analog disp lay is set to show speedometer read- ings, the digital screen will automati cally display the t achometer (option 1). If the analog is set to show th e tachometer , the di[...]

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 cycl e 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 Prog ram The Engine Program automatically di splays the engine coolant tempera- ture, engine hours, electrical system voltage level and fuel level (if equipped). On machines equipped w ith altimeter sensor and ambient air temperature sensors, altitude and ambi ent air temperature wi[...]

44 FEA TURES Instrument ation MFD Digit al Display Programs Engine Prog ram 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 ten sec- onds to switch between standard an[...]

45 FEA TURES Instrument ation MFD Digit al Display Programs History Program The History Program automatically di splays electrical system voltage level and fuel level (if equipped). While in the History mode, press the SET button to view maximum vehicle speed, maximum engi ne rpm or the current service 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 designated service interval (set by the user), the gauge provides a reminder that service is due. "SErVCE" will flash in th[...]

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 is n't working properly , replace the battery . Replace- ment batteries are available from your dealer . 1. Remove the plenum from the under- side of the hoo d. 2. Locate the black bat[...]

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 batte ry 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 compartme[...]

50 THE PERFECT FIT IQ Front Suspension Adjustment s Independent Front Suspension (IFS) Break in the suspension for approx imately 150 miles (24 0 km) before making any fine-tuning adju stments. Settings will vary from ri der to rider , depending on rider weight, vehicle speed, riding style, an d trail conditions. W e recommend starting with factory[...]

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 ch ange front shock sp r[...]

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! Changin g shock valving requires special tools and a sound knowledge of mechanical theory , tool use, and shop procedures to perform[...]

53 THE PERFECT FIT Rear Suspension Adjustment s Rider weight, riding style, trail co nditions, and vehicle speed all af fect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However , all sus- pension design s and adjustment s involve a compromis e, or [...]

54 THE PERFECT FIT IQ Rear Suspensi on Adjustment s Initial Spring Preload Setting (Sag Method) T o set up the re ar 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 n[...]

55 THE PERFECT FIT IQ Rear Suspensi on Adjustment s T orsion Spring Preload T o adjust rear torsion spring preloa d, 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 Suspensi on Adjustment s Limiter Strap Positi on (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 press[...]

57 THE PERFECT FIT IQ Rear Suspensi on Adjustment s Suspension Coupling On all Polaris snowmobile rear suspensi ons, there are two torque arms that control the mo vement of the rail beam. Pr ior to the advent of sus- pension coupling, thes e torque arms could mo ve independently of each other . Rear suspens ion coupling links the move ment of the f[...]

58 THE PERFECT FIT IQ Rear Suspensi on Adjustment s Rear T o Front Coupling and th e Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque ar m and limits the am ount of in depen- dent movement be tween the rear torque and the front torque arm. Adjusting the RRSS either all[...]

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

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

61 THE PERFECT FIT Accessories Polaris offers a wide range of accesso ries for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and 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 t[...]

62 THE PERFECT FIT T raction Products Stu d s Before equipping your snowmobile wi th traction prod ucts, be aware of the laws in your area pertaini ng to the use of traction p roducts. Use only Polaris traction prod ucts on your snowmo bile. T rack warran- ties are void if track damage or fa ilure results from improper or exces- sive stud installat[...]

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

64 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on th e checklist for proper operation or condition before each use of the snowmobile. Pr ocedures are outlined on the refer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspection items. Item See Page Drive Belt Condi tion 105 S teering System 6[...]

65 PRE-RIDE INSPECTIONS Before St arting the Eng ine Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of prop er operation. W ARNING! Operating the vehicle with worn , damaged, or malfunctioning components could result in se[...]

66 PRE-RIDE INSPECTIONS Before St arting the Eng ine n Hood Latches The hood of the snowmobile p rotects the operato r from moving parts as well as aiding in sound emission con trol and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that th e hood straps ar e in good condition[...]

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

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

69 PRE-RIDE INSPECTIONS Before St arting the Eng ine n T rack Inspection W ARNING! Operating the snowmobile with a damaged track increa ses the possibility of track failure, which cou ld c ause loss of control resulting in serious injury or death. Always inspect the tr ack for damage before using the vehicl e. W ARNING! Use of traction products suc[...]

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

71 PRE-RIDE INSPECTIONS S t art the Engine and Check n Engine S top Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine . Pull it up to allow restarting. n Ignition Switch Make sure the engine stops when th e ignition switch is turned to OF F . n Lighting Check the headlight (hig h and low beam),[...]

72 OPERA TION Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of fuel with one pint of Polaris injection o il for each five gal- lons of fuel. This, in addition to th e lubrication supplie d by the injection system, will assure prop[...]

73 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 77. NOTICE: Serious engine damage can occur without the proper lu brication. Check the oil tank level often during t he first tank of fuel. If the oil level doesn't go down, contact your dealer immediately . Oil Recommendations This s[...]

74 OPERA TION T rack W arm-Up A loose track or flying debris could caus e serious injury or death. S tand clear of the front of the machine and the moving track. Never hold the snowmob ile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Be sure the rea r support is st[...]

75 OPERA TION Fuel Safety Gasoline is highl y flammable and explosive u nder certain conditions. • Always exercise extreme caution w henever handling gasoli ne. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or allo[...]

76 OPERA TION Fuel For peak performance, Polaris recomm ends the use of 91 oc tane or higher fuel. Although 87 octane fuel is usable, some eng ine perfor- mance will be lost and fuel econ omy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing mor e than 10% ethanol (including E85) . NOTICE: Operating with obstructed fue[...]

77 OPERA TION n Oil Low Oil Indicator Light The low oil indicator light will alert th e operator if the oil level is low . V isually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 73 for oi l recommendations. Low Oil Level Maintaining the proper oil level w ill prevent system aeration and possi- ble loss o[...]

78 OPERA TION n Engine S top Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly . Pull the switch up to the RUN position to allow restarting. n Throttle Safety Switch The throttle safety switch is designed to stop the engi ne whenever all pressure is removed from the throttle lever and the throttle cab[...]

79 OPERA TION n Throttle Lever W ARNING! An imprope rly 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 u rn the ignition sw[...]

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

81 OPERA TION Electronic Reverse (PERC t ) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the yellow reverse button fo r 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. n Emergency S topping The following chart list[...]

82 OPERA TION Daily St orage At the end of each ride, park the snowmobi le on a level surface and sup- port it at the rear with an appropri ate track stand. The track should be suspended approximat ely 4" (10 cm) of f the groun d. Remove the key and cover the snowmobile. To w i n g Do not use the fr ont bumper to pull or drag the sn owmobile. [...]

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

84 MAINTENANCE Polaris Recommended Maintenance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform se rvice checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log begin ning on page 133. The recommended maintenance schedul e on your snowmobile[...]

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 ri ding conditions. When inspection reveals the need for replacement parts , always use genuine Polaris parts, available from your Polaris dealer . I - Inspect (clean, adjust, tighten, l[...]

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 R 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) 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 F[...]

88 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 85 and before sea sonal storage. When operating in heavy , wet snow conditions, lubr icate every 500 miles (800 km). Lack of lubrication will adversely[...]

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 n Chaincase Oil Check the chaincase oil leve l at the intervals outlined in the Periodic Main- tenance T able beginnin g 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 (80[...]

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 du e to the preser- vative added during the assembly p rocess. 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 a lw[...]

93 MAINTENANCE Spar k P l u g s Normal Sp ark Plug The normal insulator tip is gray , ta n 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 white insulator tip ind icates overheating, ca[...]

94 MAINTENANCE Int ake Filters The intake foam filter limits snow ingestion into the intake system. When operating in loose po wder 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 au thorized Polaris dealer . Do not attempt to clean or service[...]

95 MAINTENANCE Oil Lines Inspect oil line condition ev ery 1000 miles (1600 km). Oil Filter The oil filter is located at the side of the oil tank. Have your dealer chang e the oil filter and bleed the system annually or every 1000 miles (1 600 km). Tip : The direction of the arrows in dicates the direction of flow through the fil- ter . Exhaust Sys[...]

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

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

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 n 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, approximat ely 1/16" (1.5 mm). A kit is avail- able for replacing brake pads. See your dealer . W ARNING! Brake fa [...]

101 MAINTENANCE Brakes n Brake Fluid After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapid ly absorbs moisture from the air . The mo isture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possib[...]

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

103 MAINTENANCE Light s Removing Halogen Bulbs Tip : Do not touch a halogen bulb with bare fi ngers. Oil from skin leaves a resi- due, causing a hot spot that will shorten the life of the lamp. If fi ngers do touch the bulb, clean it with an alcohol-moistened towel. 1. Remove the plenum co ver- ing from the headlight assembly . 2. Lift the rubber b[...]

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 th an normal clutch eng agement or an unusual vibration or shift pattern, see your dealer immedia tely . Do not ope[...]

105 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition an d tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and exce ssive looseness. Replace the belt if any of these conditions exist. Se e Drive Belt T roubleshooting on page 123. Fo[...]

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 of f. W ait for the engine to co[...]

107 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. Tip : T o ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning th e identification numb ers so that you can read them. If required, separate the sheaves as outlined in t[...]

108 MAINTENANCE T rack Replacement When replacing the track, always inst all a track having the lug size rec- ommended for your mo del. See your Polaris deale r . NOTICE: Installing tracks with larger lugs on machines equip ped with coolers will result in d amage to the cooler o r tunnel. Always install a track having the lug size recommended for y[...]

109 MAINTENANCE T rack Lubrication W ARNING! Operating with insufficient lubr ication be tween the rail slide and track guide clips can cause track failure, loss of vehicle contro l and loss of braking ability , which can result in seri ous injury or death. Avoid operati ng for extended periods on ice and other surfac es that have little or no snow[...]

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 parts. Never perform track measur ement or adjustments with the engin e running. T rack adjustment is critical for prop er handling. Always maintain cor- rect te[...]

111 MAINTENANCE T rack T ension 4. Check for specified slack between th e 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 adjus ting screws as necessary to provide equal adjustment on bo th sides of the track. 8. [...]

112 MAINTENANCE n T rack Alignment Periodically check that the track is centered and running ev enly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support t he 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 slowl[...]

113 MAINTENANCE S teering System Steering Inspection and Adjustment Check all steering system fa stener s weekly and before a lon g ride. T ighten any loose fasteners. + + + + +[...]

114 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment or adjust ment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustmen t. See your Polaris deale r . W ith the handlebars in a straight ahead position, and with vehicle weight compressing t[...]

115 MAINTENANCE S teering System n Ski Skags W ARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causi ng seri ous injury or death. See your dealer's studding chart fo r recommended skags. If you install longer or more aggressive carbide skags than the orig inal equipment, it may also be necessa[...]

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 componen ts. See page 1 18 for the part n umbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, an d waxing the hood, chas[...]

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

118 POLARIS PRODUCTS Part No. Descripti on Engine L ubricant s 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (gal.) 2872347 [...]

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

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

121 TROUBLESHOOTING Engine T r oubleshooting 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 fo r spark. 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. •[...]

122 TROUBLESHOOTING IQ Comfort Suspension T r oubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper stat ic 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[...]

123 TROUBLESHOOTING Drive Belt Wear/Burn Cause Solution Driving at low RPM Drive at higher RP M. 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 machine in extremely cold weather and warm it up. Break machine loos e from the snow . T owing at low RPM Do not tow [...]

124 W ARRANTY Service And W arranty Information Obt aining Service and W arranty Assist ance Read and understand the service data and the Polaris warranty informa- tion contained in this manual. Contact your Polaris dealer for replace- ment parts, service or warranty . Y our dealer receives frequent updates on changes, modifications and tips on sno[...]

125 W ARRANTY Service And W arr anty Information Polaris Anti-Thef t System The Polaris anti-theft system (P A T S) monitoring program is designed to aid owners of registered snowmobil es in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying the proper law enforcement officials, the ow[...]

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

127 W ARRANTY Limit ations of warran ties and remedies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES 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 [...]

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

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

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

131 W ARRANTY U.S.A. EP A Emission s Limited Warranty This emissions li mited warranty i s in addition to t he Polaris standard limite d warranty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S. Environme[...]

132 W ARRANTY U.S.A. EP A Emission s Limited Warranty The exclusive remedy for breac h of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts. THE REME DIES SET FOR TH IN THIS LIMITE D W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF T[...]

133 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 servi ces performed on the snowmobile. DA TE MILES (KM) TECHNICIAN SER VICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 1500 mi[...]

134 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SER VICE PERFORMED / COMMENTS[...]

135 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SER VICE PERFORMED / COMMENTS[...]

136 INDEX A Access Panel, Radi ator Compartm ent 30 Accessories . . . . . . . . . . . . . . . . . . . 61 Adjustable Steering System . . . . . 33-34 Apparel . . . . . . . . . . . . . . . . . . . . . . 12 Avalanches . . . . . . . . . . . . . . . . . . . . 17 B Backrest . . . . . . . . . . . . . . . . . . . . . . 30 Battery Replacem ent, MFD . . . . .[...]

137 INDEX I Ice and Snow Build- up . . . . . . . . . . . 18 IFS . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Instrumentation . . . . . . . . . . . . . . 36-49 Intake Filters . . . . . . . . . . . . . . . . . . . 94 Intake Silencer . . . . . . . . . . . . . . . . . 20 L Lamps, Repl acing . . . . . . . . . . . . . . 103 Light, High Temper[...]

138 INDEX S Suspension Performa nce Tips . . . . . 53 Suspension, Front . . . . . . . . . . . . . . 50 Switch, Stop . . . . . . . . . . . . . . . . . . . 78 Switch, Throttle Safety . . . . . . . 65, 78 T Throttle Cable Lubrication . . . . . . . 89 Throttle Lever . . . . . . . . . . . . . . 65, 79 Throttle Safety Switch . . . . . . . . 65, 78 Torque[...]