Polaris 600RR manual

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W ARNING Read, understand, and follow al l of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious inj ury or death. The engine exhaust from this product contains chemical s known to the S tate of Californi a to cause cancer , birth defects or other reprod[...]

1 WELC OME Thank you for purcha sing a Polar is vehicle , and welcome to our world-w ide family of Polaris owne rs. W e pr oudly produce an exc iting line of utility a nd re cr eationa l products. S Snowmobiles S All-te rr ain vehic les ( A TVs) S RANGER utility vehicle s S V ict or y mo to rcycl es W e belie ve Polaris sets a standa rd of exc elle[...]

2 PO L AR IS an d PO L AR IS T HE W A Y OUT are registered trad emark s of Po laris Indus t ri e s Inc . Copyri ght 2007 Pola r is Sa le s I nc. Al l i nf orm at ion c ont ai ne d wi thi n thi s publi c at i on is bas e d on t he l at e st pr oduc t inf orm at i on at t he t ime of publ ic a t ion. Due to cons t ant imp ro vem ents in the desig n a[...]

3 TABLE OF CONTENTS Introducti on 4 ............................... This section contains helpf ul informa tion for owne rs and dr ivers a nd illustrate s the loca tion of impor tant identif ication numbe rs tha t should be rec orde d in the owner ’ s manual. Safety 7 ..................................... This sec tion desc ribes sa fe ve hicle o[...]

4 INTRODUCTION Impor tant N otes for Ow ners and D ri vers After r eading this manual, store it in the snowmobile for conve nient ref er ence . It should rema in with th e snowmobile whe n the snowmobile is sold. When teach in g in experi enced o perat ors t o ride, s et up a pred eterm in ed course f or prac tice. Make sure the y know how to drive[...]

5 INTRODUCTION Pr eser vation of the Envir onm ent Polaris is committe d to supporting a n environme ntal educ ation campa ign. W e encourage gove rnme nts to adopt rigorous safe ty training progra ms that encourage prote ction of our environme nt, including wildlife a nd vegeta tion. Snowmobile clubs and other or ganiz ations are wor king together[...]

6 INTRODUCTION V ehi cle Identifi cation Num ber s Record your snowmobi le’ s id entifi catio n numbers in t he spaces provided. V ehicle Model Number : Tunnel VIN: (lower right s ide of the tunnel) Engine Ser ial Number: (right fr ont s ide of engine crank c as e)[...]

7 SAFE TY Operator S afety The following signa l words and symbols a ppear throughout this manual a nd on your vehic le. Y our sa fety is involve d when these words and symbols are use d. Beco me familia r with their mea nings befor e rea ding the manual. The safet y alert sym bol , on your vehicl e or i n thi s manual, alert s you to the potent ia[...]

8 SAFE TY Operator S afety Follow the re comme nded mainte nance progra m outlined beginning on page 60 of this manua l to ensur e that a ll critic al c omponents on the snowmobile ar e thoroughly inspec ted by your de aler a t specific mi leag e in terv als . W ARNING Dri ving a snowmobi le r equir es your f ull attent ion. DO NOT dri nk alcohol o[...]

9 SAFE TY Operator S afety Ridi ng Appar el Be p repared, b e warm an d b e comfor table whe n riding. Be aware of th e weath er forecast , es peci all y t he windchill, and dr ess accordi ng ly . See t he chart on page 19. W ARNING A void wear ing l oose clot hing or long scarves, which can become entangl ed in movi ng par ts and cause seri ous in[...]

10 SAFE TY Operator S afety Stay Clear of T r ack Y our snowmobile is propelle d by a re volving trac k that must be partia lly exposed for p roper ope ration. W ARNING Seri ous injur ies may result i f hands, feet , or clot hing become ent angl ed in t he tr ack. Be aler t when r i ding, and remain pr operl y seated t o stay clear of t he track. N[...]

11 SAFE TY Operator S afety Driver A wareness Slow down when trave ling near poles, pos ts , or o th er obs tacl es . B e esp ecial ly aler t if you’re snowmobiling afte r dark. Always be on the alert for wir e fenc es. Single strands are e specia lly dangerous, si nce th ere may be a g reat di st ance betwe en posts. Guy w ires on utility pole s[...]

12 SAFE TY Operator S afety Dis a bl e d Op e rat o rs Safe ope ration of this rider - active ve hicle r equire s good judgement and physica l skills. Opera tors with c ognitive or physical disa bilities ha ve an incr ea sed risk of loss of control, which c ould result in se rious injury or death. Rider Capacity Y our Polaris snowmobile is designed[...]

13 SAFE TY Operator S afety A valan ches Snowmobilers should alwa ys be pr operly traine d and equippe d befor e tra veling in mountainous ter rain: S T ake an aval anch e clas s S T ravel wit h exp erien ced peop le S T ravel on designa ted tra ils S Make su re each person i s equ ip ped wi th a shovel, probe and a valanche beacon. Y ou don’ t h[...]

14 SAFE TY Operator S afety Excessive S peed W ARNING High speed drivi ng, especial ly at night , could resul t in seri ous injury or death. Always r educe speed when dri ving at night or in incl ement weather . Always obser ve all laws gove rning snowmobile ope ration a nd speed limits. Alway s be ale rt a nd pa y attentio n to the tra il ahea d. [...]

15 SAFE TY Operator S afety Driving in Hilly T errain W ARNING Cli mbing a hi l l or crossing t he face of a slope may r esult in loss of balance and machi ne rol l -over , causi ng seri ous inj ury or death. Use cauti on and good judgement when drivi ng in h illy terrain . Use e xtra c aution w hen ope rating in hilly te rr ain. If climbing a hill[...]

16 SAFE TY Operator S afety Drive Belt Do not ope r ate t he eng ine wit h the drive be lt r emov ed. Any servic ing that r equire s opera tion without a belt must be pe rforme d by your dea ler . Oper ation of the e ngine with the be lt removed ma y result in injur y or dama ge to the e ngine. Intake Silencer Do not oper at e the engine w ith the [...]

17 SAFE TY Operator S afety Inadequate S now Condi tions W ARNING Do not dr ive f or pr olonged per i ods on blackt op, gr avel, or ice. Doing so could cause i rr eversi ble t r ack damage and lead t o seri ous inj ur y . Since snow provides the only lubrication for the power slide suspension and, on liquid coole d models, cooling for the engine, a[...]

18 SAFE TY Operator S afety Dr ivi ng Respons ibly Every snowmobile handles dif feren tly , and even the most docile conditions may become danger ous if oper ators dr ive imprope rly . If you’re ne w to snowmobiling, acqua int yourself with the machine and with wha t it will an d won’ t do unde r va rious conditions. Eve n seasone d driver s sh[...]

19 SAFE TY Operator S afety Windchill/T emperatur e Charts The following inf ormation is provide d to help you dete rmine w hen temper ature s beco me dange rous for riding. WIND CHILL CHART ( ° F) Wind Speed in MPH Act ual Ther momet er Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -2 0 -25 -30 -35 -40 -4 5 Equivalent T emperatur e ( ° F) [...]

20 SAFE TY Safety D ecals and Locations W arning decal s have been placed on t he snowmobil e for your prot ect io n. R ead and fo ll ow t he in st ruct io ns o f the decal s on t he sno wmo bi le careful l y . If any of th e decals d epi cted i n t his m anual differ from the decals o n your snowmobil e, always read and follow the ins tru cti on s[...]

21 SAFE TY Safety D ecals and Locations T rack W arning The track warning d ecal is l o cat ed on th e rear of the tunnel: Passenger W arning This snowmobile is designed for one opera tor only . A “No Passenger ” warnin g decal i s l ocat ed on t he low er cons ol e: + +[...]

22 SAFE TY Safety D ecals and Locations Operation W arning +[...]

23 SAFE TY Safety D ecals and Locations Operation W arning[...]

24 FEATURES AND CONTROLS 1. Brak e Lever 2. Oil Light ( 600RR only) 3. T ach om eter 4. T empera ture Light 5. Engine Stop Switch 6. T hrottle Contr ol 7. Choke Control 8. Reco il S tart er Hand le 9. Fue l Filler Cap 10. Park B rake Lock 1 1. Headlight Dimmer S witch 12. Handleba r Grip W armer / Thumbwarme r Switch 13. T ethe r Switch 14. Master [...]

25 FEATURES AND CONTROLS 1. Handlebar 2. Winds hield 3. Headlight 4. Hood 5. Nosepan 6. Skis 7. T rack 8. Suspension 9. S now Flap 10. T aillights 1 1. Seat 9 4 11 10 7 8 5 6 1 2 3[...]

26 FEATURES AND CONTROLS Polar is DRA GON Ignition System (600 IQ R acer) Y our snowmobile is equippe d with an ignition syste m fea ture that improves c ompetition pe rfor mance by incre asing e xhaust system temper ature. The DRAGON Ign ition System provide s maximum “hol esh ot ” perform ance fo r racin g app li cat ion s. W ARNING DRAGON mo[...]

27 FEATURES AND CONTROLS Polar is DRA GON Ignition System (600 IQ R acer) DRAGON Mode Op eration 1. W arm up the engine and trac k. See page 54. 2. When s tag ed at th e st arti ng line, depre ss and hold the DRAGON butto n on the left handleba r (1). 3. Slowly advance the thr ottle to the wide -open position while kee ping the button depre ssed. 4[...]

28 FEATURES AND CONTROLS Electr onic Rever se (PE RC t ) (600RR) Electr onic reve rse will activa te only if t he engine RPM is below 4000. If your mac hine is running at an altitude of over 6000 fe et, adjust the ignition setting as descr ibed below . Always make sure the ve hicle is stopped and the engine is running at idle be fore shifting to re[...]

29 FEATURES AND CONTROLS Electr onic Rever se (PE RC t ) (600RR) Disengaging Reverse 1. S top the snowmobile and leave the engine idling. 2. P ush the rever se button for one second and re lease . The engine will slow and be gin to rota te f orwa rd. The light on the ta chome ter will shut of f. 3. Apply the throttle slowly to make sure the tra nsm[...]

1 3 2 4 30 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents Independe nt Front S uspensi on (IFS ) Brea k in the suspension f or about 150 mile s (240 km) be fore making any f ine-tuning a djustments. Settings will vary f rom rider to rider , depending on rider weight, vehicle spe ed, riding style, and trail conditions. W e rec ommend st arti ng[...]

31 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents W ARNING Always ver if y ski al ignment before m aking adj ustment s to t he I FS. See page 92 to check al ignment . If the skis ar e misal igned, see your dealer , as the camber adjustm ent may al so be af f ected. The tension a t which the shoc k coil spring is set is ca lled spring preload. [...]

1 32 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents Front S hock S pri ng Pr eloa d Increasi ng s pri ng prel oad wi ll i ncrease ski-to-gr ound pressur e. Dec rea sing spring preloa d will decrea se ski-to-ground pressur e. Whe n adjusting, be sure the springs on both the lef t and right sides of the mach ine are a t the same adjustment. A=L [...]

33 THE PE RFECT FIT IQ Fr ont S uspension Adjustm ents Shoc k V alving W alker /Evans shocks c an be r evalve d if spring pre load alone isn’ t suf fic ient and f urther adjustment is de sired to c ontrol suspension stif fne ss. W ARNING Changing shock val ving on W alker/ Evans shocks requi res speci al t ool s and a sound knowledge of mechanica[...]

34 THE PE RFECT FIT Rear S uspension Adjustments Rider we ight, riding style, trail conditions, and ve hicle spe ed a ll af fec t suspension a ction. Each rear sus pen si on can be adj us ted t o su it ri der preferen ce and deliver e xce llent perf ormanc e for a given se t of conditions. However , all suspension designs and adjustments involve a [...]

35 THE PE RFECT FIT IQ Rear S uspension Adjustm ents Rear T o rsion Spring T ension T o adjust re ar tor sion spring ten sion, rotate the three -position ca m using the engine spark plug tool. Dif ferent r ate tor sion springs are ava ilable if a firme r ride is desire d. Contact your deale r for more info rmat io n. The following inf ormation is p[...]

36 THE PE RFECT FIT IQ Rear S uspension Adjustm ents Suspension Cou pling On all P olaris snowmobile re ar suspensions, there ar e two torque arms that contr ol the move ment of the rail be am. Prior to the advent of suspension coupling, these torque ar ms could move independently of each other . R ear susp ension coupl in g links t he movement of [...]

37 THE PE RFECT FIT IQ Rear S uspension Adjustm ents Rear Rear S cissor Stop ( RRS S) The rea r rea r scissor stop (RRSS) couples the movement of the rear torque ar m with the front torque arm and limits the amount of independe nt movement betwee n the rear torque a nd the front torque arm. Adjusting the RRSS either allow s mo re weight to tran sfe[...]

38 THE PE RFECT FIT IQ Rear S uspension Adjustm ents W eight T ransfer During Acceleration IQ Rear Rear Scisso r Sto p (R RSS) The pr efe rre d method for c ontrolling we ight tran sfer du rin g accel erati on of t he IQ rear suspension is by adjusting the RRSS . Use the scissor stop tool (1) locate d in your tool kit to make the a djustments. T o [...]

39 THE PE RFECT FIT Handlebar Adjustm ents Handlebar with Riser Block 1. Remove the handlebar cover to expose the handleba r mounting hardwa re. 2. Using a 1/4” Allen wrench, loosen the tw o bolts on the bottom of the riser or the two bolts on the t op of the riser , depending on the type of adjustme nt requir ed. 3. Adjust the handlebar to the d[...]

40 THE PE RFECT FIT Accessor ies Pol aris o ff ers a wi de range of accesso ries for your snowmobi le to hel p make each ri de more enj oyable. S ee your dealer for a com plet e li st o f accesso ries . Use only Pol aris part s and accesso ries on your Pol aris snowmobi le. Use of unap prov ed part s and acces sori es m ay resul t i n: S Non-c ompl[...]

41 THE PE RFECT FIT Accessor ies T rac tion Pr oducts Another w ay to tailor your mac hine is to install tra ction pr oducts. See your deale r about installing studs and/or ca rbides. Ma ny track s with deep lug designs cannot be studded, but your dealer will be able to offer advice an d as si st ance. NOTE: Befor e equippi ng your m achine wi th t[...]

42 THE PE RFECT FIT Accessor ies CAUTION Aggressi ve studdi ng patt er ns may requi re gr indi ng pr otr uding st ud bolt s fl ush to pr event i dl er wheel damage. Maint ain t r ack tensi on on studded tr acks on the t ight side of t he spec to pr event heat exchanger damage. Center of st ud must be at least 1 1/8 ″ (2. 86 cm) f r om outsi de ed[...]

43 THE PE RFECT FIT Accessor ies W ear Str ips Polaris IQ models are manufa cture d with tunnel we ar str ips or wear strip coole rs installe d. T o avoid exce ssive tunne l wear , tunnel wea r strips must be installe d whene ver tr ack studding is use d. W ear str ips are designed for a spe cific stud length. See your deale r ’ s studding chart [...]

44 PRE -RIDE IN SPECTI ON S Pre - Ride Ch ecklis t Inspec t all ite ms on the c heck list for pr oper ope ra tion or c ondition before each use o f th e sn owm obi le. P rocedu res are o u tlined on the referenced pages . Lo ok for a checkm ark ( n ) on the ref erenc ed page s to locate the pre -ride inspe ction items. I t e m S e e P a g e Item S [...]

45 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine W ARNING W orn, damaged, or malfunct ioni ng component s may cause seri ous i njur y or deat h. Bef or e star ti ng the engi ne, check al l component s t o be sure of proper oper ati on. Read a nd Under stand Y our Owne r ’ s Manual Read t he Owner ’ s M anual co mp let ely an d refer to[...]

46 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Hydraulic Br akes Always ch eck th e following ite ms to assur e proper ope ration bef ore starting the engine . Brake L ever T ravel Sq ueeze t he brak e lev er . It should move no close r to the ha ndgrip than 1/2 ″ (1.3 cm) . A smalle r distanc e indicate s low brake fluid level or ai[...]

47 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Par king Brake Lever Lock Y our snowmobile may have a parking brak e lever loc k located over the brake lever . Use the par king brake lever loc k only when you wa nt the machi ne t o remai n st ati on ary; fo r examp le, when p arked o n an incl i ne for a per iod of five minutes or less.[...]

48 PRE -RIDE IN SPECTI ON S Befor e S tarti ng the Engine n Check for Proper Operation of Steering System Manually tur n the skis comple tely to the right a nd to the left. If any dif fic ulty is encounte red, c heck f or ice and snow build- up that may be obstructing the stee ring linkage . Make sure a ll greasa ble components are prop erly l ub r[...]

49 PRE -RIDE IN SPECTI ON S Star t the E ngine and Check Befo re start in g th e engin e, al ways refer t o all s afety w arni ngs perta ining to snowmobile operation. Neve r start your snowmobile without checking all compone nts to be sure of proper oper ation. See Befor e Starting t he Engine beginning on page 45. n Engine St op Switc h: Chec k t[...]

50 OPERATION Engine B r eak -In No single action on your part is as import ant to long, trouble-free mach ine life as prope r brea k-in of a new or re built engine. Alwa ys premix the initial fue l and futur e fue l as outlined in the table s on page 51. CAUTION Excessive heat build- up duri ng the f i rst three hour s of oper ati on wi ll damage c[...]

51 OPERATION Engine B r eak -In Fuel Re comm endati ons CAUTION Using f uels wi th a l ower t han r ecommended octane or operat ing wi th obstr ucted f uel systems wil l r esult in seri ous and cost ly engi ne damage. Always use t he recomm ended fuel s for your machine. 600 IQ Racer Fu el Always use pr emium non-oxygena ted (92 oc tane ) fuel. 600[...]

52 OPERATION Engine B r eak -In Fuel Re comm endati ons W ARNING Gasoli ne is hi ghly f lam mable and expl osive under certai n condit ions. S Always exerc ise ext rem e caut ion whenever handling gas oline. S Always ref uel with t he engine st opped, and outdoor s or in a well ventilat ed area. S Do not over fill t he t ank. Do not f ill the t ank[...]

53 OPERATION Star ting the E ngine Sta rti ng a Cold E ngine Do not depress the throttle until the engine star ts. 1. Attach the tether c ord to the te ther sw itch. 2. Pull the kill switch (shut-of f switch) up to RUN . 3. F lip the choke toggle to FULL C HOKE . 4. Grasp the starter ha ndle and pull slowly until the rec oil engages, then pull abr [...]

54 OPERATION Engine and T r ack Warm -Up W ARNING A loose t rack or flyi ng debr is coul d cause seri ous personal injur y or death. Stand cl ear of the fr ont of the machi ne and the m oving t rack. Never hol d the snowmobi le up or stand behind i t while warm ing up t he tr ack. Do not use excessive t hr ott le dur ing w arm- up or when the tr ac[...]

55 OPERATION Slide Rail and T rack Cooling CAUTION Inadequat e cooli ng and lubr icat ion wi ll lead to over heat ing of the sli de rai l and tr ack, r esult i ng in pr ematur e wear and fail ure. Reduce speeds and fr equentl y dri ve int o fr esh snow t o all ow adequate cool ing and pol ishi ng of t he sli de rai l and t r ack surf aces. A voi d [...]

56 OPERATION Car bur etion Pro per carbur eto r adju st ment i s crit i cal. A lean m i xtu re (too m uch ai r , too little fue l) may r esult in piston burning, bea ring fa ilure , or comple te engine fa ilure . A rich mixture (too much fu el, too little air) may foul plugs an d cause gener ally poor e ngine per forma nce. A lean mixture ma y be c[...]

57 OPERATION n Engine S top Sw itch Push down on the engine stop switch (1) to stop the engine in an emer gency . T o restart the engine, pull the switch up to the ON position. Em er gency Stoppi ng The following cha rt lists methods for stopping the snowmobile in the eve nt of an eme r genc y . Refer to page 57 f or more information a bout the eng[...]

58 OPERATION Daily Storage At th e end of each ride, p ark the sno wmo bi le o n a l evel su rface and support it at the rear with an a ppropria te trac k stand. The tra ck should be suspended a pproxima tely 4 ″ ( 10 cm) of f the ground. C over the mac hine with an appropr iate cove r . T owing W ARNING Ob jec ts to we d with a ro pe h a ve n o [...]

59 MAINTENANCE Em ission C ontr ol Infor m ation Any qu ali fied rep air sh op or qu ali fied p erson m ay m aint ai n, rep lace, o r repa ir the emission contr ol device s or systems on your snowmobile. Em ission Con trol Label Y our snowmobile is equipped at the time of sale with an emission control inf ormation ( ECI) labe l and a f actor y-inst[...]

60 MAINTENANCE Polar is Recom m ended Maintenance Pr ogr am T o ensure many trouble-free miles of snowmobiling enjoyme nt, follow rec ommende d re gular ma intena nce a nd ser vice c hec ks outlined in this manu al. R ecord s ervices perfo rmed i n th e Main ten ance Record at t he rea r of this manual. The rec ommende d maintenanc e sche dule on y[...]

61 MAINTENANCE Per iodic Maintenance Inter val T able The following char t is a guide based on ave rage r iding conditions. Y ou may ne ed to incr ease fre quency ba sed on r iding conditions. When ins pect i on rev eals t he need for rep lacem ent part s, al ways us e gen ui ne Polaris pa rts, ava ilable f rom your Pola ris de aler . See P Frequen[...]

62 MAINTENANCE Per iodic Maintenance Inter val T able See P Frequency Item Page 150 mi. (240 k m) 500 mi. (800 k m) 1000 mi. (1600 k m) 2000 mi. (3200 k m) Pre- Season Brakes Hose Rou tin g -- I I I I Hos e Condition -- I I I I Fluid Leak s -- I I I I Brak e Pads 77 I I I I Brake Disc -- I I I I Parking Brakes 47 I I I I Brak e Sy s tem 45, 77 I Br[...]

63 MAINTENANCE Per iodic Maintenance Inter val T able See P Frequency Item Page 150 mi. (240 k m) 500 mi. (800 k m) 1000 mi. (1600 k m) 2000 mi. (3200 k m) Pre- Season Chassis Sk i T oe A lignment -- I I I Sus pension Mounting Bolts -- I I I I I Steering F astener s -- I I I I C Rear Sus pens ion Fas teners -- I I I I I Sus pension S hoc k O il -- [...]

64 MAINTENANCE Lubri cation Lack of lubrica tion will adve rsely a f fec t your ride a nd the life of compone nts. Lubricate with Polaris Pre mium All Sea son Grea se a t 500 miles (800 km) initially , ever y 1000 miles (1600 km) afte r that, and before o ff-season s to rage each year . A greas e gun ki t, co mp let e wit h grea se and ada ptors, i[...]

65 MAINTENANCE Lubri cation Front S uspens ion T wo compone nts of the IQ front suspension a nd stee ring requir e lubrica tion. S Grea se the left and right spindles. R aise the front end of the ma- chine to per mit better gre ase e ntry into the spindle are a. S Lubrica te the steer ing post U-joint. Throttl e Cable Lubric ate the throttle c able[...]

66 MAINTENANCE Lubri cation n Chaincase Oil Level Chec k the chainca se oil level at the interv als outlined in the maintena nce c harts beginning on page 60. T o ch eck t he oi l lev el, p lace t he m achi ne on a l evel s urface. Th e oi l level should be betwee n the “safe ” marks on the dipstick (A). Add Polaris synthetic c hainca se oil th[...]

67 MAINTENANCE Spar k Pl ugs A spar k plug with a hea t range too high will cau se engine damage . A spark plug w ith a he at range too low will ca use e xcessive fouling and engine malf unctioning. In sele cting a spa rk plug he at range for pr oduction, a manuf acture r assumes that the engine will be opera ted under extr eme hea vy duty conditio[...]

68 MAINTENANCE Spar k Pl ugs Spark plug c ondition is indicative of engine opera tion. The spar k plug firing end c ondition should be re ad a fter the engine ha s bee n warme d up and t he veh icl e has been d riv en at hi gh er speed s. Imm edi at ely check th e spark p lug fo r correct col or . W ARNING A hot exhaust system and engi ne can cause[...]

69 MAINTENANCE Intake Filter The intake f oam filte rs limit snow ingestion into the intake syste m. Whe n opera ting in loose powder snow , check the top of the foa m filter s periodic ally to remov e any accum ul ati on of snow . CAUTION Operat ing t he snowmobi le wi th t he int ake fi lt er s removed may cause carbur etor i cing. The result wi [...]

70 MAINTENANCE V aria b le Exh au st Sy st em (VES) Maintena nce of the VE S i s limited to a periodic inspection and clea ning of system c omponents. Every 1000 to 2000 miles (800- 1600 km), bring the ma chine to a n authoriz ed Polar is dealer to have the VES di sass em bl ed, i nsp ected , and clean ed. NOTE: T o ensure maxi mum per for mance an[...]

71 MAINTENANCE Car bur etor The n um ber s tam ped in th e end of t he m ain jet i nd icat es t he j et s ize. The jet installe d at the time of manufactur e is not n eces sari ly co rrect for your ele vation. It’ s your dealer’ s responsibility to make sure the cor re ct main jet is installe d. CAUTION Operat ing t he snowmobi le wi th i ncorr[...]

72 MAINTENANCE Exhaust S ystem Check the e xhaust system for wear or da mage a t approximate ly 1000 miles (1600 km) . T o inspect, allow the engine a nd exha ust system to cool comple tely . Open the hood and inspec t the muf fler and pipes f or cracks or dam age. C heck for weak o r mi ssi ng ret ai ni ng sp rin gs o r damper /support gr ommets. [...]

73 MAINTENANCE Engi ne Cooli ng Coola nt Mixtur e The coolan t supplied in t he system is a 50/50 mixture of ethylene -glyc ol and distilled w ater . This mixture pr ovides prote ction again st freezi ng at t emp eratu res to -3 4 ° F (-37 ° C). If great er prot ecti on is requ ired , th e percent age o f ant ifreeze t o wat er may be increas ed.[...]

74 MAINTENANCE Engi ne Cooli ng Flushing the Cooling Sy stem T o ensure tha t the coolant maintains its ability to protect the engine , the system should be complete ly drained e ver y two years a nd a fr esh 50/ 50 o r 60/ 40 mi xt ure of ant i freeze and dis tilled wa ter should be added. This service must be done when the engine is cold. Ask you[...]

75 MAINTENANCE Engi ne Cooli ng Bleeding the Cooling System 3. T ip the snowmobile slightly onto its right side. Cycle the RPM from idle to e nough RPM (4000) to get coolant to flow , but not enough to enga ge the c lutch. This allows air to blee d from the r ear crossove r tube. NOTE: There must be enough coolant f l ow to pur ge the ai r f r om t[...]

76 MAINTENANCE Drive Chain T ension T o ob tai n correct ch ain t ens io n: 1. Rotate the driven clutc h counter clockwise to move all chai n sl ack to t he ten si on er side. Lock the brake lever lo ck, or h ave an ass is tan t h ol d the bra ke lever f irmly . 2. Loosen the adjuster bolt jam nut (A). 3. Fi nger tighten the adjuste r bolt (B) unti[...]

77 MAINTENANCE n Hydr aulic Br ake Inspection Freque ntly inspec t the brake l ever res erve. Sq ueeze t he brak e lev er . It should move no close r to the ha ndgrip than 1/2 ″ (1.3 cm) . A smaller di st ance i ndi cat es l ow brak e fluid leve l or air in the hydraulic syste m. Refer t o t he b rake bl eedi ng informa tion on page 80. Brak e pa[...]

78 MAINTENANCE Br akes Br ake C ompone nts 1. B rake C ali per 2. C hai ncase 3. Brake Disc 4. Backing Plate 5. Brak e Pad M ateri al (R eplace when t hi ckn ess i s les s th an 1/ 16 ″ ). Excessive Br ake Lever T ravel Hydraulic br ake s are self- adjusting, but if excessive bra ke pad clea ranc e develops, as descr ibed on page 77, the machine [...]

79 MAINTENANCE Br akes Br ake Fl uid W ARNING Aft er openi ng a bott l e of br ake fl uid, always discar d any unused port ion. Never st ore or use a parti al bot t le. Brake f lui d is hygr oscopic, meaning it rapi dly absor bs moist ur e fr om the ai r . The moistur e causes t he boil ing temper at ure of the brake f lui d to dr op, whi ch can le[...]

80 MAINTENANCE Br akes Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spongy brake le ver ac tion. Bleed the system befor e opera ting the snowmobile. W ARNING Operat i ng the vehi cle wi th a spongy br ake lever can result in loss of brakes, which could cause an acci dent and l ead t o seri ous inj ury or death. [...]

81 MAINTENANCE Headlights Headlight Adjustment The hea dlight may be adjusted for ver tical aim using the following proce dure: 1. P lace t he s nowm ob il e on a lev el s urface wi th th e headl i ght approxima tely 25 f ee t (7.6m) fr om a wa ll. 2. Measure the distanc e fro m the floor to the center of the hea dlight and m ake a m ark o n th e w[...]

82 MAINTENANCE Headlights NOTE: Do not t ouch a halogen bul b wit h bar e fi ngers. Oil from skin leaves a resi due, causi ng a hot spot that wi ll shorten t he l if e of t he lamp. Rem ovi ng Haloge n Bulbs - High/Low B eam 1. P inch the ends of the spring (1) togethe r an d lift until it re lea ses from t he s pri ng ret ain er . 2. Lift spring c[...]

83 MAINTENANCE Clutch S ystem Peri od ical ly in sp ect t he cl utch sh eaves for dam age, wear , o r bel t residue . T o maintain optimum pe rfor mance , clea n with non-oil base d clea ners such as isopropyl alcohol. W ARNING If you become aware of hi gher than normal clutch engagement or an unusual vibr ati on or shift pat ter n, see your dealer[...]

84 MAINTENANCE Clutch S ystem n Dr ive B elt Condi tion Periodic ally c hec k the condition a nd tension of the drive belt, and always c arr y a spare belt. F or improve d drive-a way during e xtreme ly cold t emp eratu res, r emov e the belt an d warm it t o room t emp eratu re. Reinsta ll it befor e star ting the snowmobile. Drive B elt Removal C[...]

85 MAINTENANCE Clutch S ystem n Drive B elt Deflection Measu re bel t defl ecti on wi t h bot h clut ches at res t and i n th eir ful l neutra l position. Place a straight edge on the belt (A) and apply downwa rd pre ssure while measur ing at point B. This measur ement should be 1 1/4”. Dr ive B elt Adj ustme nt 1. Loosen the 7/6” jam nut on th[...]

86 MAINTENANCE T or que S top If your snowmobile is equipped with an engine torque stop ( 1), periodic ally ch eck tor que stop clearan ce. W it h clu tch es in proper a lignment, the torque stop clea ra nce should be a minimum of .010 ″ to a maximum of . 030 ″ from the engine ca se (2). Adjust if neces sary , and lo ck th e jam nut. 2 1[...]

87 MAINTENANCE Chain T ension Maintain the prope r cha in tension as outline d on page 76. Fall T une -Up For maximum perfo rmanc e, arra nge for a fa ll servic e tune-up with your Po lari s deal er . His ex peri enced and t rai ned serv ice tech ni cian wi ll k eep your mac hine in pea k opera ting condition. T ool K it A too l ki t i s in clu ded[...]

88 MAINTENANCE T rack Maintenance W ARNING Moving par t s can cut and cr ush body part s. When perf ormi ng t he checks and adjust ments r ecommended on t he fol lowi ng pages, s tay cl ear of all moving part s. Never perf orm tr ack measurement or adj ustm ents wit h the engine r unning. T rack T ensio n T rack adjustme nt is critica l for prope r[...]

89 MAINTENANCE T rack Maintenance I f t he tr ac k nee ds adjust m ent ( co nti nued) : 8. Repeat measur ement on the other side of the track . NOTE: Check more f r equentl y when machine i s new . 9. Start the machine a nd slowly rotate the tr ack at lea st five revolutions. Let the tra ck c ome to a stop ( do not apply bra kes). 10. Ch eck track [...]

90 MAINTENANCE T rack Maintenance T rack Inspection W ARNING Broken t rack r ods are a ser i ous safet y hazard. They can cause a rot ati ng tr ack to come of f the m achine, which could cause seri ous inj ury or death. Never oper ate w it h a damaged tr ack. Never r otat e a damaged tr ack under power . Using a hoist, safe ly lift and support the [...]

91 MAINTENANCE Steer ing System Steering Inspection and Adjustment Each week, or b efore a long ri de, ch eck all f ast eners and t ig ht en if necess ary . S peci fical ly ch eck fast eners m arked wi th a + .[...]

92 MAINTENANCE Steer ing System Sk i Ali gnment W ARNING Impr oper ski al ignment or adj ustm ent may cause loss of steer ing contr ol, resul ti ng in ser ious i njur y or deat h. Do not at tempt to change the ski ali gnment or camber adj ustment . See your Polar i s dealer . W ith the handleb ars in a str aight ah ead position, and w ith vehic le [...]

A 93 MAINTENANCE Steer ing System n Ski S kags W ARNING W orn ski s and/ or skags wi ll adversely af fect handl ing. Loss of vehi cle contr ol m ay resul t, causing seri ous inj ury or death. See your deal er’ s studdi ng chart for recommended skags. If you instal l longer or mor e aggressi ve carbi de skags than t he ori gi nal equi pment, it ma[...]

A 7/16 ″ (1.1 cm) 94 MAINTENANCE Suspension Maintenance n Rail Slide W ear Measur e slide thickness at sever al points along the rail. Have your dealer repla ce the slide w hen it’ s w o r nd o w nt ot h et o po f the wea r limit indicator groove (A) . Do not operate the snowmobile if slide thickness meas ures l ess t han 7/ 16 ″ (1. 1 cm). n[...]

95 MAINTENANCE Extended S tor age Of f-se ason or extende d storage of your snowmobile requir es preve ntive measur es to a id against dete riora tion and to pr olong the usef ul life of many co mponents. Cleaning and Preser vation Proper stor age sta rts with clea ning, washing, and waxing the hood, chass is , an d pl ast ic part s. W ipe do wn re[...]

96 MAINTENANCE Extended S tor age Engi ne and Car bur etor P rotec tion Proper pr epar ation of the engine a nd fue l system is vital to the preve ntion of rust a nd corr osion on prec ision engine pa rts during st orage. When ever t he m achi ne i s s to red fo r a peri od o f m ore t han 6 0 days,the engine must be fogged with fogging oil. Follow[...]

97 MAINTENANCE Extended S tor age Electr ical Connections Sep arate elect rical con nect or bl ocks an d clean co rros ive bu il d-u p from conn ecto rs. Lub ricat e or p ack co nnect or b lo cks wit h d iel ectri c greas e and re- connec t. See page 99 for the part numbers of Polaris products. Repl ace worn or frayed elect rical wire an d con nect[...]

98 MAINTENANCE T ranspor ting the S nowm obile Whe neve r the snowmobile is transpor ted: 1. T urn the fuel valve clockwise to OFF to shut of f the fuel supply (1). Tu r n t h e v a l v e counter -clockwise to ON to turn the f uel supply on (2). NOTE: T h ef u e lv a l v ei s locat ed under the hood. 2. Be sure the fuel ca p is installed corr ec tl[...]

99 POLARIS PRODUCTS Part No. Descrip ti o n Engine Lubr icant s 2870791 Fogging Oi l ( 12 oz. Aerosol) 2873023 Synthet ic 2- Cycle Raci ng Oi l ( gal. ) 2871098 Premi um 2- Cycle Engi ne Oi l ( qt. ) 2871097 Premi um 2- Cycle Engi ne Oi l ( gal. ) 2871240 Premi um 2- Cycle Engi ne Oi l ( 2.5 gal .) 2871721 Premi um Gol d Synthet ic 2- Cycl e Engine[...]

100 TROUBLE S HOOTING Engine T roubleshooting CAUTIO N: Unless you have e xperie nce a nd training in two-c ycle engine re pair , see your dealer if te chnic al problems ar ise. Proble m Proba ble C aus e Solutio n Err a ti c e ngine oper a ti ng RPM du rin g accelera- tion or lo ad var i at i ons Driv e clutch bin d in g Driv en clu tch malfu ncti[...]

101 TROUBLE S HOOTING Engine T roubleshooting Proble m Proba ble C aus e Solutio n Noise i n drive system Broke n drive c l utc h com ponent s Bearin g failu re/ chain case, jack sh aft, or fr ont dri ve s haf t Driv e b elt su rface flat spot s Driv e chain loo se or worn, s pr oc ket t e et h broke n -SEE YOUR DEALER. -SEE YOUR DEALER. -Insp ect [...]

102 TROUBLE S HOOTING Engine T roubleshooting Proble m Proba ble C aus e Solutio n Engine t ur ns bu t fails to start Fau lty ig nitio n No fue l t o engi ne Floode d engi ne (nor - mal situ atio n cau sed by too m uch c hok- ing) Poor engi ne c ompre s - sion -Rem o ve sp ark plu g (s) an d replace w ith new plu g (s). If engi ne still fails to st[...]

103 TROUBLE S HOOTING Suspension T r oubleshooti ng Proble m Solution (per form only one c hange a t a tim e) Rear su sp en sio n bo tto ms to o easily -I nc re a se tors i on spr i ng pre l oad -I nc re a se rea r s hock c ompr e ss i on dam ping by t urni ng s c re w cl oc kwi se -I nc re a se t or si on spr ing wir e di am et e r (s e e your dea[...]

104 TROUBLE S HOOTING Belt T r oubleshooti ng Belt W ear/Burn Be lt W ea r/B urn Dia gnos is Causes Solut ions Driv ing at low RPM Dri ve a t highe r RPMs . Ge ar t he ma chi ne down. Che ck bel t def l ec t ion. Insu fficient w arm-u p W a rm the e ngi ne at l e as t f ive mi nut es . T a ke the dr ive be l t of f the mach in e in extremely co ld [...]

105 WARRANTY Ser vic e And Warranty I nform ati on Obtaining Service and W arranty Assistance Read and unde rstand the ser vice data a nd the Polaris warr anty informa tion containe d in this manual. Contact your Polaris de aler for replacem ent part s, s ervi ce or warrant y . Y our d ealer recei ves frequ ent updates on c hange s, modifications a[...]

106 WARRANTY Li mit e d W arra nt y Pola r is Sa l es Inc. , 2100 Highwa y 55, Medi na , MN 55340, provi de s a ONE YEAR LIM - ITED W ARRANTY on all c ompone nts of t he Pola r is s nowmobi le a ga ins t de fe c ts i n ma te r ia l or wor kmans hi p. This wa rr a nty cove r s the pa r ts a nd la bor cha r ges for r e pai r or replacem en t o f d ef[...]

107 WARRANTY Limita tions of warranti es a nd remedie s ALL IMPLI ED W ARRANTIES (I NCLUDING BUT NOT LIMI TED T O THE IM- PLIED W ARRANTIES OF MERCHANT ABILITY AND FI TNESS FOR A P AR TICU- LAR PURPOSE) ARE LIMI TED IN DURA TIO N TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W AR- RA NT IE S NO T S T A T ED IN T HIS[...]

108 WARRANTY Conditions and Ex cl usi ons In or de r t o qua li f y for wa r ra nty , t he produc t mus t ha ve be en pr ope rl y s et up and te s te d by a Po laris D ealer (if ap plicab le). F ailu re o f an y d ealer to perfo rm th e req u ired veh icle P re- De li ve ry Ins pec t ion, pe r for m al l appl i ca bl e se r vic e bul le t ins a nd [...]

109 WARRANTY Pol ari s Se cond Y ear E ngine Se rv ice Contr ac t Sec ond Y e ar Engi ne Se r vic e Cont ra c t i s st a ndar d on a ll eli gibl e ne w and unus e d snow mobil e s t ha t we r e Snow Che cke d t hrough a n a uthor iz e d Pol ar is deal e r dur i ng the Ma rc h/ Apri l Snow Chec k promoti on. The fr e e Sec ond Y ear Engi ne Se rvi c[...]

11 0 WARRANTY Exported V ehicles EXCEPT WHERE SPECIFI CALL Y REQUIRED BY LA W , THERE I S NO W AR- RANTY OR SER VICE BULLETI N COVERAGE ON THIS VEHI CLE IF I T IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. Th is po licy d oes no t app ly to v eh icles that hav e received auth o rizatio n fo r e xpor t f rom Pola r is[...]

111 WARRANTY Snow mobi le Engi ne Em is sions Lim ited W ar ra nty Th is sn o wm ob ile en g ine em issio ns lim ited warran ty i s in ad d itio n to th e Po laris stan dard li mi te d wa r ra nt y for s nowmobi le s . Pola r is I ndus tr ie s I nc . war r ant s t hat t he ne w engine , i ncl uding al l pa rt s of i ts e mi ss i on- cont r ol sys t[...]

11 2 MAINTENANCE RECORD DA TE MILES/KM TECHNI CIAN SER VICE PERFO RMED / COMMENTS 150 mi. (240 km ) 500 mi. (800 km ) 1000 mi. (1600 km) 2000 mi. (3200 km)[...]

11 3 MAINTENANCE RECORD DA TE MILES/KM TECHNI CIAN SER VICE PERFO RMED / COMMENTS[...]

11 4 MAINTENANCE RECORD DA TE MILES/KM TECHNI CIAN SER VICE PERFO RMED / COMMENTS[...]

11 5 INDEX A Accesso ries 4 0 -4 3 .................. Altitu d e Ign itio n S ettin g 29 .......... A v alan ch es 1 3 .................... B Bef or e Sta rt i ng the Engi ne 45- 48 ...... Bel t T roubl e shoot i ng 104 ........... Ble e ding t he Cooli ng Sys te m 67, 74-75 . Bleed in g the B rak e Sy stem 80 ........ Bra ke Compone nt s 78 ......[...]

11 6 INDEX J Jetting G u idelin es 56 ............... L Light ing C hec k 49 ................. Lubri c at i on 64-66 .................. M Ma int e nanc e I nte r val T abl e 61-63 ...... Ma int e nanc e Pr ogra m 60 ............ Man euv erab ility 16 ................ O Oil F ilter 69 ...................... Oil Le ve l, I nje c ti on (600RR) 55 ....[...]