Polaris 600 Widetrak IQ manual

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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. 9922596 Rev 01 Printed in USA P antone 425C[...]

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[...]

The text is printed on 100% recycled with 40% post-consumer waste (PCW).[...]

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

2 POLARIS and THE W A Y OUT are registered trademarks 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 and quality of production components, some minor discrep- ancies may [...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This section contains helpful info rmation for own e rs 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 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 provin cial governments across the sn ow- belt to adopt rigorous safety traini ng programs that encourage protection of our environment, includ ing wildlife and vegetation. Snowmobile clubs and o ther orga[...]

7 INTRODUCTION V ehicle Identification Numbers Record your snowmobile’ s identific ation numbers and k e y 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 Polari s key blank with o ne 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 symb ol indicates a potential personal injury ha zard. WA R N I N G A W ARNING indicate[...]

9 SAFETY Operator Safety Follow the recommended mainte nance program outlin ed beginning on page 77 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 ti on. DO NOT drink alcohol or use drugs or medications bef[...]

10 SAFETY Operator Safety St ay Clear of T rack Y our snowmobile is propelled by a revo lving track that must be part ially 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 proper throttle, brak e 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 artme nt of T ransportation (DOT) label. Approved helmets in Europe, Asia and Ocean[...]

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

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

15 SAFETY Operator Safety Excessive Speed W ARNING! High speed driving, especially at night , could result in serious injury or death. Always reduce speed when drivin g at night or in inclement wea ther . Always observe all state an d local laws governing snowmobile opera- tion and speed limits. Al ways be alert and pay attenti on to the trail ahea[...]

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 terf ere with the steering of you r 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 righ[...]

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

21 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only 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 mos t doc ile con di- tions may become dangerous if oper ators drive improperly . If you’re new to snowmobiling, acquaint your self with the machine and with what it will and won’t do under various conditions. Even seasoned driv- ers should spend s[...]

23 SAFETY Operator Safety Windchill/T emperature Chart s The following informatio n is p r ovi ded to help yo u d et ermine 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 [...]

24 SAFETY Safety Decals and Locations W arning decals hav e been placed on 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 operat or and one passenger have a warn- ing decal on the console. For more information on operating with a pas- senger , see page 13. W ARNING This vehicle is designed for oper ator and “ONE” passenger only . T rack W arning W ARNING St ay clear of tr ack . Do[...]

26 SAFETY Safety Decals and Locations Reverse W a rning Polaris snowmobiles equipped with st andard reverse an d 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 befo re and while backing up. • A[...]

27 SAFETY Safety Decals and Locations Operation W arning An operation warning decal is pres ent on the console of all Polaris snowmobiles: W ARNING • T o avo id serious inj ury or death, read and understand all warnings and the Owner ’ s Manual befor e operation. If manual is missing, con- t a ct a Polaris dealer for a replace ment. • This ve[...]

28 FEA TURES 3 4 5 6 13 2 1 10 11 12 18 14 15 16 17 20 19 21 9 7 8 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. Windshield 7. Mountain Bar 8. Handlebar 9. Fuel Filler Cap 10. Seat 1 1. Backr est 12. T aillights 13. Cargo Ca rrier 14. Rear Bu mper 15. Snow Flap 16. T rack 17. Suspension 18. Grab Handle Heater Switch 19. Backrest Adjust[...]

29 FEA TURES 2 6 7 15 8 9 13 14 3 11 1 0 1 4 5 1. Glove Box 2. MFD Display 3. Ignition Switch 4. 12-V olt DC Outlet 5. Shifter 6. Work Light Switch 7. Brake Lever 8. Handlebar Grip W armer Switch 9. Thumbwarmer Switch 10. Throttle Control 1 1. Engine S t op Switch 12. Electronic Reverse Button 13. MFD Control Switch 14. Headlight Dim mer Switch 15.[...]

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. Seat Latch Release the[...]

31 FEA TURES Adjust able Headlight s Move the headlight adjuster to raise or lower the headlight beam. • Move the adjuster to the left to lower the beam. • Move the adjuster to the right to raise the beam. Glove Box The glove box is a heated dry storage area inte nded for drying wet gloves. Do not use the glove box for items that could be da ma[...]

32 FEA TURES Cargo Carrier W ARNING! Overloading or towing improperly can alter vehicle handling and can cause loss of control. • Do not exceed the carg o carrier capacity . • Always reduce speed and allow greater distance for braking and turning when carrying cargo or a passenger , or whe n towing. • Always secure cargo before operating vehi[...]

33 FEA TURES Passenger Grab Handle The position of the passenger grab handles can be adjusted for rider preference. 1. Remove the adjustment bolt. 2. Reposition the grab handles to one of the two adjustment positions on the grab handle tube between the operator seat and the passenger seat. 3. Reinstall the adjustment bolt and tighten securely . 12-[...]

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

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

36 FEA TURES Instrument ation MFD Settings The MFD control switch allows yo u 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. MFD settings can be made with the engine running or with the engine off. If the engine is of f,[...]

37 FEA TURES Instrument ation MFD Settings Spe edometer/T achometer If your model is equipped w ith both analog and digital displays, the speedometer and tachometer can be vi ewed in either display . If the ana- log display is set to show speedomet er readings, the digital screen will automatically display the tachometer (option 1). If the analog i[...]

38 FEA TURES Instrument ation MFD Digit al Display Programs Press and release the MODE button to cycle through the three MFD pro- grams: Performance, Engine and Hist ory . 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. Perform[...]

39 FEA TURES Instrument ation MFD Digit al Display Programs Performance Program T rip Settings T rip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge. The fuel symbol and the last fuel bar on the MFD gauge (if equipped) will blink when the fuel level reaches 1/8 of a tank. The T rip F o[...]

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

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

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

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

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

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

46 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 fro m the under- side of the hoo d. 2. Locate the black b[...]

47 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[...]

48 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 stm ents. 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 factor[...]

49 THE PERFECT FIT Rear Suspension Adjustment s Rider weight, cargo weight, riding style, trail conditions and vehicle speed all af fe ct suspension action. Each rear suspension can be adjusted to suit rider preference and deliver the best performance for a given set of conditions. Howe ver , all suspen- sion designs and adjustments involv e a comp[...]

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

51 THE PERFECT FIT Rear Suspension Adjustment s T orsion S pring Preload T o adjust rear torsion spring preloa d, rotate the three-position cam using the engine sp ark plug tool. This adjust ment is easier to make if tension is relieved from the spring. Exerci se extreme caution if you use this method of adjustment, and fo llow the steps below care[...]

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

53 THE PERFECT FIT Rear Suspension Adjustment s Shock Compres sion V alving The rear track shocks for this mode l are gas char ged shocks . The va lv- ing on the gas charged shocks is pre-set.[...]

54 THE PERFECT FIT Handlebar Adjustment s Use the following steps to adjust ha ndlebar angle at the h andlebar block. 1. Remove the mo untain bar . 2. Remove the hand lebar cover . 3. Using a 7/16" wrenc h, loosen the four nuts on the bottom of the adjuster block. T urn the handlebar to the left or right for access to the back nuts. If nec- es[...]

55 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[...]

56 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 tio n 98 S teering System 5[...]

57 PRE-RIDE INSPECTIONS Before St arting the Engine 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 malfunctioni ng components could result in se[...]

58 PRE-RIDE INSPECTIONS Before St arting the Engine n Hood Latches The hood of the snowmobile p rotects the op erato 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[...]

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

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

61 PRE-RIDE INSPECTIONS Before St arting the Engine n T rack Inspection W ARNING! Operating the snowmo bile with a damaged track increases 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 such[...]

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

63 PRE-RIDE INSPECTIONS S tart 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), [...]

64 OPERA TION Fuel Safety Gasoline is h ighly flammable and e xplosive under 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 refuelin g. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or all[...]

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

66 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil bottle when refuel ing. See page 70. NOTICE: Serious engine damage can occur without the proper lu brication . Check the oil bottle level often during the first tank of fuel. If the oil level doesn't go down , contact your dealer immediately . Oil Recommendations [...]

67 OPERA TION S tarting the Engine 1. T urn the key to the ON position. NOTICE: Engaging the starter when the engine is run ning WILL result in serious engine damage, especially if the tr ansmission is in reverse. Never engage the starter when the engine is runni ng. 2. Pull the engine stop switc h up to the RUN position. 3. If equipped with electr[...]

68 OPERA TION Rest arting an Engi ne If the rider stop s the engine by pushing the engine stop switch down, restart the engine using the normal st arting procedure. If the engine fails to start using the normal procedure: 1. Push the engine stop swit ch down to the OFF position. 2. T urn the key to the OFF position. 3. W ith both switches OFF , squ[...]

69 OPERA TION Fuel Resistor This snowmobile is equipped with a feature that allows the engine controller to select the proper operating software based on the type of fuel being used. The proper fuel resistor mus t be installed to match the type of fuel you are using. The snowmobile comes from the factory with the resistor installed that should be u[...]

70 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. If oil is not visible, continued opera- tion may cause serious engine damage. Add o il before further op eration of the snowmobile. Low Oil Level Maintaining the proper oil level w ill pre[...]

71 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 snowmobile and th e moving track. Never hold the snowmobil e up or stand behind it while warming up the track. Do not use excessive throttle dur- ing warm-up or when the track is free-han ging. Be sure the rear supp or[...]

72 OPERA TION n Engine S top Switch Push down on the engine stop switch to ground out the ig nition 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 ca[...]

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

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

75 OPERA TION Daily St orage At the end of each ride, park the snowmobi le on a lev el surface and su p- port it at the rear with an appropri ate track stand. The track should be suspended approximat ely 4" (10 cm) off the ground. Remove the key and cover the snowmobile. To w i n g For your safety , do not attempt to use a tow hitch until you&[...]

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

77 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 131. The recommended maintenance schedul e on your snowmobile[...]

78 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[...]

79 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 91 II II Brake Disc -- II II Parking Brakes 60 II II Brake System 59, 91 I Brake Fluid 59 R FUEL MANAGEME[...]

80 MAINTENANCE Periodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessar y) C - Clean R - Replace L - Lubricate Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season CHASSIS Ski T oe Alignment -- II I Suspension Mounting Bolts -- II I I I S teering [...]

81 MAINTENANCE Lubrication n Gearcase Oil Level Check the gearcase oil level at the intervals outlined in the maintenance charts beginning on page 77. Change the gearcase oil after the first 500 miles (800 km), then every 1000 miles (1600 km) or seasonally . T o check the oil level, place the snowmobile on a level surface. The oil level should be b[...]

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

83 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Pr emium All Season Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 78 and before sea sonal storage. When operating in heavy , wet snow conditions, lubr icate every 500 miles (800 km). Lack of lubrication will adversel[...]

84 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 prolon ged 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 l[...]

85 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[...]

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

87 MAINTENANCE Oil Lines Inspect oil line condition ev ery 1000 miles (1600 km). Oil Filter The oil filter is locate d at the side of th e oil tank. Have your dealer change the oil filter and bleed the system annually or every 1000 miles (1600 k m ). Tip : The direction of the arro ws indicates the direction of flow through the filter . Exhaust Sys[...]

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

89 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[...]

90 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! S team and hot liquids will cause bu rn 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, conta[...]

91 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 59. 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 fail[...]

92 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 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 possib[...]

93 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 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 opera[...]

94 MAINTENANCE Light s Removing Halogen Bulbs Tip : Do not touch a halogen bulb with bare fi ngers. Oil fro m skin leaves a resi- due, causing a hot spot that will shorten the life of the lamp. If fi nge rs do touch the bulb, clean it with an alcohol-moistened towel. 1. Remove the plenu m cov- ering from the headlight assembly . Lift the rubber boo[...]

95 MAINTENANCE Light s Inst alling Halogen Bulbs 1. Hold the bulb by its metal base an d install it into the wire harness. 2. Insert the bulb into the housing. 3. Connect the spring to the housing. 4. Carefully flip the spring back into the housin g, placing it aroun d the wire harness. 5. Reinstall the plenum coveri ng on the headlight assembly . [...]

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

97 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 engagement or an unusual vibration or shift pattern, see your dealer immedia tel y . Do not oper[...]

98 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 121. For[...]

99 MAINTENANCE Clutch System Drive Belt Adjustment Belt deflection should be adjusted wi thout removing the clutch from t he jackshaft. 1. Loosen the 7/16-inc h jam nu t on the belt width adjuster . 2. Using a 1/8-inch Allen wrench , ad just the threaded set screw as needed. Tip : T urn the set screw in (clockwise) to increase th e distance betwe e[...]

100 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 a it for the engine to com[...]

101 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 from the left side of the vehicle. If required, sep[...]

102 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[...]

103 MAINTENANCE T rack Lubrication W ARNING! Operating with in sufficient lubr ication between the rail slide and track guide clips can cause track failure, loss of vehicle contro l and lo ss of braking ability , which can result in seri ous injury or de ath. Avoid operating for extended periods on ice and other surfac es that have little or no sno[...]

104 MAINTENANCE T rack T ension W ARNING! Moving parts can cut a nd crush bod y 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 [...]

105 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. [...]

106 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 h e 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 slow[...]

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

108 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment o r 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 a head position, and with vehicle weight compressing[...]

109 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[...]

110 MAINTENANCE Battery W ARNING! Improperly connecting or disconnecti ng battery cables can result in an explosion and cause serious injury or death . When removing the battery , always disconnect the negative (black) ca ble first. When reinstalling the battery , always connect the negative (bl ack) cable last. Battery Removal 1. Release the seat [...]

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

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

113 MAINTENANCE Matte Clear Coat Clea ning (if equipped) Matte finish products are prone to tr apping dirt, oils and other contami- nants. Polaris Industries recommends cleaning with warm water and a mild dish detergent. Use a soft spon ge to gently rub the surface and rinse with clean warm water . For stubborn stains such as grease or oil use a ci[...]

114 MAINTENANCE Extended Storage Battery Maintenance Remove the battery and recharge it as o utlined on page 1 12. Store the battery in a cool, dry place. Controls and Linkage Lubricate all bushings and cables at the intervals outlined in the Periodic Maintenance T able beginning on page 78. Bearings Grease the jacks haft and drive sha ft clutch si[...]

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

116 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2877882 VES Gold Plus Synthetic 2-Cycle Engine Oil (qt.) 2877953 VES Gold Plus Synthetic 2-Cycle Engine Oil (2 qt.) 2877883 VES Gold Plus Synthetic 2-Cycle Engine Oil (gal.) 2877884 VES Gold Plus Synthetic 2- Cycle Engine Oil (2.5 gal.) 2877887 VES Gold[...]

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

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

119 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Engine turns but fails to start Faulty ignition • Install new spark plug(s). If engine still fails to start, check for 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. • I[...]

120 TROUBLESHOOTING Suspension T roubleshooting Problem Solution Rear suspension bottoms too easily • Set static sag (see page 50). Adjust torsion spring blocks or install optional torsion spri ngs to achieve correct sag dimensions. Rides too stiff in rear • Check for bindi ng suspension components and grease all pivot points. • Set static sa[...]

121 TROUBLESHOOTING Drive Belt Wear/Burn Cause Solution Driving at low RPM Drive at higher RPM. Gear the machine down. Check belt deflection. Insufficient warm- up W arm the engine at least five minutes. T ake the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from th e sn ow . T owing at low RPM Do not tow[...]

122 W ARRANTY Service And W a rranty Information Obt aining Service and Warranty Assist ance Read and understand the service data and the Polaris warranty 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[...]

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

124 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 .[...]

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

126 W ARRANTY Conditions and Exclusions In order to qualify for warranty , the product must have been properly set up and tested by a Polaris Dealer (if 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[...]

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

128 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[...]

129 W ARRANTY U.S.A. EP A Emission s Limited W arranty This emissions li mited warranty is in additi on to the Polaris standard limited warran ty 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 applic a- ble U.S. Environm[...]

130 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive remedy for breac h of this limi ted 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 TH IS LIMITED W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE T O ANY PERSON FOR BREACH O[...]

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

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

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

134 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 55 Air Pollution . . . . . . . . . . . . . . . . . . . 6 Apparel . . . . . . . . . . . . . . . . . . . . . . 12 Avalanches . . . . . . . . . . . . . . . . . . . . 17 B Backrest . . . . . . . . . . . . . . . . . . . . . . 30 Battery Charging . . . . . . . . . . . . . 111-112 Installation [...]

135 INDEX G Gauge Cleaning. . . . . . . . . . . . . . . . . 47 Gearcase Oil L evel . . . . . . . . . . . . . . 81 Glove Box . . . . . . . . . . . . . . . . . . . . . 31 Grab Handle Adj ustment . . . . . . . . . 33 H Handlebar Adjus tments . . . . . . . . . . . 54 Headlight Adjus ting . . . . . . . . . . . . . 31 Helmet . . . . . . . . . . . . . . .[...]

136 INDEX S Starting the Eng ine . . . . . . . . . . . . . 67 Starting the Engine , Restarting . . . . 68 Steering Inspec tion . . . . . . . . . . . . 10 7 Steering System . . . . . . . . . 58, 107-109 Stop Switch . . . . . . . . . . . . . . . . . . . 72 Stopping the Engine. . . . . . . . . . . . . 68 Stopping the Snowmobile . . . . . . . . 68 Stor[...]