600 IQ Racer Snowmobile Owner's Manual for Maintenance and Safety
WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more.
POLARIS®, IQ® and DRAGON® are trademarks of POLARIS Industries Inc. Copyright 2015 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner’s manual. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 This section describes safe vehicle operation and identifies warning labels and their locations. Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general representations. Your model may differ. Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.
INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment.
INTRODUCTION Vehicle Identification Numbers Record your snowmobile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced. NOTE: If installing an aftermarket tunnel wrap, do not cover the tunnel certification, tunnel VIN or emissions certification labels with the wrap.
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
SAFETY Operator Safety Follow the recommended maintenance program beginning on page 65 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger. They will reduce your alertness and slow your reaction time. Snowmobiles are capable of traveling at high speeds.
SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. WARNING! 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 snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious injury or death.
SAFETY Operator Safety Riding Apparel Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval.
SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. WARNING! Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Do not allow disabled persons to operate this vehicle. Survival Preparation For your safety, always ride in a group of other snowmobilers. Always tell someone where you're going and how long you expect to be gone.
SAFETY Operator Safety Rider Capacity Your POLARIS snowmobile is designed for a single rider only. Do not carry a passenger. Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead.
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 distinguish. Make sure the way is clear before crossing railroads and other roads and highways.
SAFETY Operator Safety Mountainous Terrain Riding Mountainous terrain operation, even for experienced riders, can present conditions and situations that could result in serious injury or death. Please review all of the information about riding in mountainous terrain on the following pages of this manual. WARNING! An avalanche can occur at any time, in any conditions and on any slope.
SAFETY Operator Safety Mountainous Terrain Riding Get the Safety Gear In addition to carrying a spare belt, spark plugs and tools on each snowmobile, each person in your riding group should wear the recommended snowmobile riding apparel and carry (on their person) the following survival items when riding in mountainous terrain: • A digital avalanche beacon with new “fresh” alkaline batteries • An avalanche probe • A compact shovel and hand saw • A backpack (preferably an avalanche air bag backpack) • Emerge
SAFETY Operator Safety Mountainous Terrain Riding Get to Know Your Safety Gear Following the safety gear and apparel recommendations will increase your chances of survival if you encounter an avalanche or become stranded in the backcountry, but even experienced and properlyequipped snowmobilers, hikers and skiers perish in avalanches or succumb to hypothermia.
SAFETY Operator Safety Mountainous Terrain Riding Get Avalanche Safety Training POLARIS recommends you and all members of your riding group participate in an avalanche safety course. Visit www.avalanche.org/ education or scan the QR code for education and training resources. Get the Forecast Make a riding plan based on the current avalanche and weather forecast. It is important to remember that overnight weather conditions may have created unsafe riding terrain that was considered safe the day before.
SAFETY Operator Safety Mountainous Terrain Riding Get Out of Harm’s Way • Before riding, always tell a responsible person (i.e. at the lodge or gas station) where your group is going. • Never ride alone. Always ride in a small, manageable group. Riding in a large group makes it more difficult to track riders or find missing members. • Go “one at a time”. Only one snowmobile at a time should cross, ascend or highmark a slope.
SAFETY Operator Safety Mountainous Terrain Riding Get to Know Your Mountain Snowmobile Always practice riding your mountain snowmobile in a safe, open, flat area before attempting your first ride in mountainous terrain. This is especially important for low-elevation riders who are not accustomed to riding a snowmobile designed for deep snow. Do not ride in mountainous terrain until you are comfortable riding and controlling your snowmobile in deep snow.
SAFETY Operator Safety Mountainous Terrain Riding Avalanche Awareness Avalanches are a matter of timing. A steep slope can be safe one day, but unsafe the next day due to changing weather and wind conditions. • Always review the user instructions provided with your safety equipment and follow the recommendations for maintenance, testing and use. Always test your safety equipment to ensure it works properly before riding in mountainous terrain.
SAFETY Operator Safety Mountainous Terrain Riding North American Public Avalanche Danger Scale Avalanche danger is determined by the likelihood, size and distribution of avalanches. Danger Level 5 Extreme 4 High 3 Considerable 2 Moderate 1 Low Travel Advice Likelihood of Avalanches Avalanche Size and Distribution Avoid all avalanche terrain. Natural and human-triggered avalanches certain. Large to very large avalanches in many areas. Very dangerous avalanche conditions.
SAFETY Operator Safety Ice and Snow Build-up WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.
SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the machine and keep it from rolling freely downhill. WARNING! When driving on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, which may result in brake failure.
SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. CAUTION! Operation of the engine with the belt 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. Intake Silencer Do not operate the engine with the intake silencer or filter removed. NOTICE: Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches.
SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the machine and with what it will and won't do under various conditions. Even seasoned drivers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding.
SAFETY Safety Labels and Locations Warning labels have been placed on the snowmobile for your protection. Read and follow the instructions of the labels and other warnings on the snowmobile carefully. If any of the labels depicted in this manual differ from the labels on your snowmobile, always read and follow the instructions of the labels on the snowmobile. If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement.
SAFETY Safety Labels and Locations Operation Warning The operation warning label is located on the console. WARNING • To 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 of high speeds. Buried objects or uneven terrain can cause loss of control. Reduce speed and use extreme caution when operating in unfamiliar terrain.
SAFETY Safety Labels and Locations Operation Warning Competition ONLY Warning (under hood) “No Passenger” Warning Track Warning Competition ONLY Warning This warning label is located under the hood on the upper left console. WARNING This snowmobile is a competition model only and is not manufactured for, nor should it be used on public land or trails. The use of this snowmobile should be limited to participation in sanctioned competition events upon a closed course.
FEATURES 1 3 2 4 5 6 7 8 9 11 12 1. 2. 3. 4. 5. 6. 7. 8. 9. 13 10 15 14 Headlight Dimmer Switch Ignition Switch/Tether Switch Master Cylinder Handlebar Pad Engine Stop Switch Throttle Control Recoil Starter Handle Hold Down Straps Fuel Filler Cap 16 10. 11. 12. 13. 14. Choke Control Hand/Thumbwarmer Switch Brake Lever Parking Brake Lock DRAGON Ignition System Switch 15. Tachometer 16.
FEATURES POLARIS DRAGON Ignition System Your snowmobile is equipped with an ignition system feature that improves competition performance by increasing exhaust system temperature. The DRAGON Ignition System provides maximum “holeshot” performance for racing applications. WARNING! DRAGON mode increases the exhaust system temperature and causes engine misfire and backfire. Flammable materials and vapors may ignite and result in fire and explosion, which may cause serious injury, death or property damage.
FEATURES POLARIS DRAGON Ignition System 1. Warm up the engine and track. 2. When staged at the starting line, depress and hold the DRAGON button on the left handlebar (1). 3. Slowly advance the throttle to the wide-open position while keeping the button depressed. 4. Release the button when the start flag drops. 1 TIP: The vehicle will launch forward at wide-open throttle.
THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
THE PERFECT FIT Front Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. To change front shock spring preload, grasp the spring and rotate it. Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension.
THE PERFECT FIT Front Suspension Adjustments Shock Valving (Walker/Evans Shocks) These shocks can be revalved if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. WARNING! Changing shock valving requires special tools and a sound knowledge of mechanical theory, tool use, and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment.
THE PERFECT FIT Front Suspension Adjustments Compression Damping Low Compression Damping Force Adjustment Increase the low compression damping force by turning the adjuster clockwise to increase the stiffness. Adjuster Softer Decrease the low compression damping force by turning the adjuster counter-clockwise to increase the softness. The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 28 clicks out from the maximum position.
THE PERFECT FIT Front Suspension Adjustments Rebound Damping Force Adjustment Increase the rebound damping force by turning the adjuster clockwise to increase the stiffness. Decrease the rebound damping force by turning the adjuster counter-clockwise to increase the softness. Softer Stiffer The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 16 clicks out from the maximum position.
THE PERFECT FIT Rear Suspension Adjustments The following information is provided only as a guideline to be used for initial suspension set-up. Your set-up may vary based on your desired riding style. Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver the best performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off.
THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Tension To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information. Cam Adjustments Soft Tension: Move the long end of the cam to the front. Medium Tension: Move the short end of the cam upward. Firm Tension: Move the long end of the cam upward.
THE PERFECT FIT Rear Suspension Adjustments Compression Damping High Compression Damping Force Adjustment Increase the high compression damping force by turning the adjuster clockwise to increase the stiffness. Softer Decrease the high compression damping force by turning the adjuster counter-clockwise to increase the softness. The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 22 clicks out from the maximum position.
THE PERFECT FIT Rear Suspension Adjustments Compression Damping Low Compression Damping Force Adjustment Increase the low compression damping force by turning the adjuster clockwise to increase the stiffness. Decrease the low compression damping force by turning the adjuster counter-clockwise to increase the softness. The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 28 clicks out from the maximum position.
THE PERFECT FIT Rear Suspension Adjustments Rebound Damping Force Adjustment (Rear track suspension only) Increase the rebound damping force by turning the adjuster clockwise to increase the stiffness. Softer Decrease the rebound damping force by turning the adjuster counter-clockwise to increase the softness. Stiffer Adjuster The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 16 clicks out from the maximum position.
THE PERFECT FIT Rear Suspension Adjustments Front Rear Scissor Stop (FRSS) The front rear scissor stop (FRSS) couples the movement of the front torque arm with the rear torque arm and limits the amount of independence between the movement of the front torque arm and the rear torque arm. When hitting a bump, the front torque arm starts to compress.
THE PERFECT FIT Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is by adjusting the rear rear scissor stop. Use the scissor stop tool located in your tool kit to make the adjustments. To decrease weight transfer under acceleration (for improved cornering), rotate the stop to a higher position. To increase weight transfer or ski lift during acceleration, move the stop to the rearward upper position.
THE PERFECT FIT Handlebar Adjustments Handlebar Position 1. Loosen the four bottom adjuster block bolts. If necessary, pry the blocks apart with a screwdriver. 2. Adjust the handlebar forward or rearward to the desired position. Tighten the bolts. Loosen top bolts to adjust handlebar angle Handlebar Angle 1. Loosen the four top adjuster block bolts. If necessary, pry the blocks apart with a screwdriver. 2. Adjust the handlebar forward or rearward to the desired angle.
THE PERFECT FIT Traction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. Use only POLARIS traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-POLARIS traction products. See your dealer about installing studs and/or carbides.
PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages.
PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death. Never start the engine without checking all vehicle components to be sure of proper operation.
PRE-RIDE INSPECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2” (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 82 or see your dealer for service. 1/2” (1.
PRE-RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the machine to remain stationary; for example, when parked on an incline for a period of five minutes or less. Brake Lever Parking Brake Lock Lock Engagement To engage the lock, squeeze the brake lever tightly and push forward on the lock. Hold the lock forward while releasing the brake lever. TIP: If the brake lever is squeezed tightly enough, the lock will move freely into place.
PRE-RIDE INSPECTIONS Before Starting the Engine Steering System WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, which could cause loss of control resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.
PRE-RIDE INSPECTIONS Before Starting the Engine Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the snowmobile.
PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Before Starting the Engine beginning on page 49. Engine Stop Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting.
OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. • • • • • Always exercise extreme caution whenever handling gasoline. Always refuel outdoors or in a well-ventilated area. Always turn off the engine before refueling. Do not overfill the tank. Do not fill the tank neck. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
OPERATION Break-In Period Engine Break-In Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine. Always premix the initial fuel and future fuel. See page 57. Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use.
OPERATION Break-In Period Engine Break-In Oil Recommendations The only source of engine lubrication for this engine comes from lubrication added to the fuel. Always premix the fuel. Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. Oils may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All POLARIS oils are compatible with each other.
OPERATION Break-In Period Engine Break-In Fuel System Deicers When using non-oxygenated fuel, use an isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures. Never use deicers or additives containing methanol. POLARIS also recommends the use of Carbon Clean. See page 106 for the part numbers of POLARIS products.
OPERATION Starting the Engine CAUTION! To avoid personal injury and/or engine damage, do not operate the recoil pull-rope starter while the engine is running. Starting a Cold Engine Do not depress the throttle until the engine starts. 1. 2. 3. 4. Attach the tether cord to the tether switch. Pull the kill switch (shut-off switch) up to RUN. Flip the choke toggle to FULL CHOKE. Grasp the starter handle and pull slowly until the recoil engages, then pull abruptly to start the engine.
OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 54 for more information about the engine stop switch. SYSTEM WHAT IT DOES THROTTLE CONDITION Brake Slows jackshaft All Choke Floods engine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Tether Switch Interrupts ignition circuit All WARNING! Excessive or repetitive use of brakes for high speed stops will cause an overheated brake system.
OPERATION Track Warm-Up WARNING A loose track or flying debris could cause serious injury or death. Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile 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 rear support is stable. WARNING Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure.
OPERATION Carburetion Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance. A lean mixture may be caused by things like fuel line restrictions, foreign matter in the carburetor or clogged fuel filters. A rich mixture may be caused by snow build-up on the pre-filter in the air intake system.
OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 inches (10 cm) off the ground. Cover the machine with an appropriate cover. Towing For your safety, do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions.
MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory-installed emissions information hang-tag. These items are required by U.S. Environmental Protection Agency regulations.
MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 121. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1000 miles (1600 km).
MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine POLARIS parts, available from your POLARIS dealer. Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Lubrication Lubrication points are indicated in the illustrations below. Front Suspension Lubricate the steering post Ujoint at the intervals outlined in the maintenance charts beginning on page 65. X Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 65 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).
MAINTENANCE Lubrication Throttle Cable Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown. X Choke and Choke Cable Lubricate the choke slide and cables lightly with oil or grease. Before turning the engine off, operate the choke intermittently to draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen.
MAINTENANCE Lubrication Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 65. Change the chaincase oil after the first 500 miles (800 km), then every 2000 miles (3200 km) or seasonally. Maintain the oil level between the “safe” marks on the dipstick. Clean the magnetic plug on the dipstick whenever checking or changing oil. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube. See page 106 for the part numbers of POLARIS products.
MAINTENANCE Spark Plugs A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. • Use recommended spark plugs with the proper gap. • Torque spark plugs to 18-22 ft. lbs. (24-30 Nm). • Always carry spare spark plugs. NOTICE: Using non-recommended spark plugs can result in serious engine damage.
MAINTENANCE Spark Plugs Spark Plug Condition Normal The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. TIP: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetor/throttle body adjustments. Wet Fouled The wet fouled insulator tip is black.
MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow. X NOTICE: Operating the snowmobile with the intake filters removed may cause carburetor icing. The result will be poor fuel economy or carburetor malfunction. Always reinstall the intake filters before operating the snowmobile.
MAINTENANCE Fuel Filter/Fuel Lines See your POLARIS dealer for replacement of the fuel filter every 1000 miles (1600 km), or annually. Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds may occur. Replace worn or damaged fuel lines promptly. NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines.
MAINTENANCE Cooling System Coolant POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 106 for the part numbers of POLARIS products. If the vehicle will be stored or operated at extremely low temperatures, greater protection may be required. Please see your POLARIS dealer. Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix.
MAINTENANCE Cooling System Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine coolant temperature becomes too hot for safe continued operation of the engine. If you must drive your machine after the high temperature indicator light has come on, drive slowly and stop frequently to allow the engine to cool down. Driving in deep snow will also help cool the engine. See your dealer for service. Add coolant if the level is low.
MAINTENANCE Cooling System Bleeding the Cooling System NOTICE: If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. Most cooling systems are equipped with a filter that should be periodically inspected or replaced. If coolant becomes low in the tank, bleed the system of trapped air. Perform the bleeding procedure when the engine is cold. 1. Allow the system to cool completely, then loosen the bleed screw and fill the reservoir to the FULL COLD mark.
MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets. CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running.
MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 50. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake pads. See your dealer. WARNING! Brake failure during operation can result in serious injury or death. Properly functioning brakes are vital to your safety.
MAINTENANCE Brakes Brake Fluid WARNING 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 rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or serious injury. Keep the master cylinder cover free of dirt and debris.
MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever. During the bleeding procedure, keep the brake handle as level as possible.
MAINTENANCE Lights Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure. 1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall. 3. Start the engine and turn the headlight switch to high beam. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 2 inches (5.
MAINTENANCE Lights Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel. Headlight Bulb Removal 1. Remove the plenum covering from the headlight assembly. 2 2. Pinch the ends of the spring (1) 3 together and lift until it releases from the spring retainer. 3. Lift spring carefully around 1 wire harness (2) and flip to outside of housing. 4.
MAINTENANCE Lights Headlight Bulb Installation 1. Hold the bulb by its metal base and install it into the wire harness. 2. Insert the bulb into the housing. 3. Connect the spring to the housing. 4. Carefully flip the spring back into the housing, placing it around the wire harness. 5. Reinstall the plenum covering on the headlight assembly. 6. Verify headlight aim. Taillight/Brake Light Replacement 1. Remove the screws securing the taillight lens. Remove the lens. 2.
MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. WARNING! If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made. All clutch maintenance and repairs must be performed by an authorized POLARIS dealer.
MAINTENANCE Clutch System Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 112. Always carry a spare drive belt for emergency use. Store the spare belt on top of the electrical box, which is mounted to the clutch cover.
MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse (if equipped). The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure forward engagement before attempting to remove the belt. 1. Stop the engine after operating in a forward motion. Wait for the engine to come to a complete stop. X 2.
MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer circumference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the break-in period. Adjust the belt ride-out after the break-in period by readjusting belt deflection. 2.
MAINTENANCE Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your POLARIS dealer. His experienced and trained service technician will keep your machine in peak operating condition. Track Maintenance WARNING 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 measurement or adjustments with the engine running. Track Inspection 1.
MAINTENANCE Track Maintenance Track Lubrication The slide rail needs snow for lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear. WARNING! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death.
MAINTENANCE Track Maintenance Track Tension Track adjustment is critical for proper handling. Always maintain correct tension and alignment. TRACK TENSION DATA CHART Suspension Slack Measurement Weight 600 IQ Racer 1/2-1 inch (1.25-2.54 cm) 10 lbs. (4.54 kg) Measurement Location 16 inches (40 cm) ahead of rear idler shaft TIP: Tension adjustments should be made only after the track is warmed up and limber. 1. Turn the engine off. 2. Lift the rear of the machine and safely support it off the ground.
MAINTENANCE Track Maintenance Track Tension 5. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 92. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. Cross Shaft Adjusting Screw Lock Nut Measure Slack Shaft Bolt p Track 16 inches (40 cm) 10 lbs. (4.54 kg) 8. Tighten or loosen the track adjusting screws to provide equal adjustment on both sides of the track.
MAINTENANCE Track Maintenance Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the machine with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions. Stop the engine and let the track come to a stop (do not apply brakes). 3.
MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary.
MAINTENANCE Steering System Ski Alignment WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or toe adjustment. See your POLARIS dealer. If the steering feels heavy, or if the snowmobile seems to pull or dart to the side, ski alignment may need adjustment. Refer to the service manual or see your dealer for this service.
MAINTENANCE Steering System Ski Skags WARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.
MAINTENANCE Suspension Maintenance Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip. Item Check suspension mounting bolts for tightness. See Page See Dealer Check rear idler wheel bolts for tightness. 93 Check rear idler adjusting bolt locknuts for tightness.
MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 106 for the part numbers of POLARIS products. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts. Wipe down remaining surfaces with a damp cloth. Clean and touch up with paint any rusted or previously painted surfaces.
MAINTENANCE Extended Storage Clutch and Drive System Remove the drive belt and store in a cool dry location. To prevent oxidation on the clutch sheaves, lubricate the sheave faces of the drive and driven clutches with a light coat of oil or POLARIS Cable Lubricant. TIP: After storage, always use acetone or alcohol to remove the oil before reinstalling the drive belt. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer.
MAINTENANCE Extended Storage Engine and Carburetor Protection Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system. If you prefer to drain the fuel tank, use the following procedure 1. Transfer unused fuel from the fuel tank to an approved fuel container using a siphon pump. Do not re-use fuel after storage. 2. Securely support the front of the snowmobile with a jack stand so the machine is elevated and the engine is tilted rearward. 3. Remove the spark plug(s).
MAINTENANCE Extended Storage Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts. Track and Suspension Moderate track tension should be maintained during summer storage.
MAINTENANCE Extended Storage Transporting the Snowmobile Whenever the snowmobile is transported: 1. Turn the fuel valve clockwise to OFF to shut off the fuel supply. Turn the valve counter-clockwise to ON to turn the fuel supply on. The fuel valve is located under the hood. 2. Be sure the fuel cap is securely installed. 3. Tie the snowmobile to the transporting unit securely using suitable straps.
SPECIFICATIONS 600 IQ Racer Capacities and Dimensions Body Style IQ Rider Capacity 1 Rider Coolant Capacity 5.7 qts. (5.4) Fuel Capacity 4 gal. (15.1) Oil Capacity N/A Chaincase Oil Capacity 11 oz. (325.3 ml) Gearcase Oil Capacity N/A Length 117 in. (297 cm) Designed Width 43.1 in. (109 cm) Height 47 in. (119 cm) Brake Type Hayes Phantom Drive Clutch Center Distance 10.625 in.
SPECIFICATIONS 600 IQ Racer Carburetor Jetting *Shaded cells indicate factory settings.
POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2878243 VES RACE 2-Cycle Engine Oil (qt./.95 l) 2878191 VES RACE 2-Cycle Engine Oil (gal./3.8 l) 2873105 SCL - Synthetic Chaincase Lubricant (qt./.95 l) 2873106 SCL - Synthetic Chaincase Lubricant (gal./3.8 l) Chaincase Lubricants Grease/Specialized Lubricants 2871312 Grease Gun Kit, All Season (3 oz./89 ml) 2871322 All Season Grease (3 oz./89 ml cartridge) 2871423 All Season Grease (14 oz.
TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine operating RPM during acceleration or load variations Drive clutch binding • SEE YOUR DEALER. Driven clutch malfunction • SEE YOUR DEALER. Harsh drive clutch engagement Drive belt worn or too narrow • Replace the drive belt. Excessive belt/ sheave clearance • SEE YOUR DEALER.
TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive system Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, jackshaft, or front drive shaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed. Drive chain loose • Inspect and adjust (or replace). Drive chain worn, sprocket teeth broken • SEE YOUR DEALER. Worn drive belt • Inspect and replace as needed.
TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause 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. • Ice may be in the fuel line, filter or pump. Add isopropyl alcohol to the fuel system.
TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bottoms too easily • Adjust torsion spring preload (see page 40). • Increase rear shock compression damping by turning screw clockwise. • Increase torsion spring wire diameter (see your dealer). Rides too stiff in rear • Check for binding suspension shafts and grease all pivot points. • Adjust torsion spring preload (see page 40).
TROUBLESHOOTING Suspension Troubleshooting Problem Solution Front end pushes • Check for worn skags. • Adjust torsion spring preload (see page 40). • Check for binding front suspension shafts and steering components, grease all pivot points (elevate front of machine). • Increase IFS preload (if equipped) (see page 35). • Install single skag (see your dealer). • Rotate RRSS to high position (see page 45). Steering is heavy • • • • Setting up for deep snow operation • Change worn rail slide.
TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up. Break machine loose from the snow. Towing at low RPM • Do not tow in deep snow. Use fast, aggressive throttle to engage clutch.
WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual. Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you.
WARRANTY Limited Warranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a 12 MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser.
WARRANTY Warranty Coverage and Exclusions Limitations of Warranties and Remedies This POLARIS Limited Warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY Warranty Coverage and Exclusions Limitations of Warranties and Remedies Lubricants and Fluids 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.
WARRANTY How to Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.
WARRANTY Exported Products EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have any questions.
WARRANTY U.S.A. EPA Emissions Limited Warranty This Emissions Limited Warranty is in addition to the POLARIS standard Limited Warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
WARRANTY U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this Limited Warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 1500 mi.
MAINTENANCE LOG DATE 122 MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 123
INDEX A D Accessories . . . . . . . . . . . . . . . . . . . 46 Air Pollution . . . . . . . . . . . . . . . . . . . 6 Avalanche Awareness . . . . . . . . . . . 21 Avalanche Danger Scale . . . . . . . . . 22 Avalanches. . . . . . . . . . . . . . . . . . 15-22 Disabled Operators . . . . . . . . . . . . . . 12 DRAGON Ignition System . . . . . 32-33 DRAGON Mode Facts . . . . . . . . . . . 32 Drive Belt . . . . . . . . . . . . . . . . . . . . . 25 Drive Belt Adjustment . . . . . . . . . . .
INDEX H Handlebar Adjustments. . . . . . . . . . . Handlebar Angle . . . . . . . . . . . . . . . . Handlebar Position . . . . . . . . . . . . . . Headlight Adjustment . . . . . . . . . . . . Headlight Bulb Installation . . . . . . . . Headlight Bulb Removal . . . . . . . . . High Compression Damping Front Track Suspension . . . . . . IFS. . . . . . . . . . . . . . . . . . . . . . . Rear Track Suspension . . . . . . . High Temperature Light . . . . . . . . . . Hood Latches . . . . . . . . . . . . . . . . . .
INDEX S T Safety Labels . . . . . . . . . . . . . . . . 28-30 Safety Symbols . . . . . . . . . . . . . . . . . 8 Scissor Stop, Front Rear . . . . . . . . . 44 Scissor Stop, Rear Rear . . . . . . . . . . 44 Shock Valving . . . . . . . . . . . . . . . . . 36 Signal Words . . . . . . . . . . . . . . . . . . . 8 Ski Alignment . . . . . . . . . . . . . . . . . 96 Ski Skags . . . . . . . . . . . . . . . . . . . . . 97 Ski Toe Settings. . . . . . . . . . . . . . . . 96 Slide Rail and Track Cooling . . . . .
For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No.
