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.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 This section describes safe vehicle operation and identifies warning decals and their locations. Features and Controls . . . . . . . . . . . . . . . . . .
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. When teaching inexperienced operators to ride, set up a predetermined course for practice. Make sure they know how to drive and control the snowmobile before allowing them to make longer trips.
INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education campaign. We encourage governments 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. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment.
INTRODUCTION Vehicle Identification Numbers Record your snowmobile’s identification numbers in the spaces provided.
Operator Safety 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, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 60 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.
Operator Safety SAFETY Riding Apparel Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 19. WARNING Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury. Always wear an approved helmet and eye protection. Helmet Wearing a helmet can prevent a severe head injury.
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.
Operator Safety 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 Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Rider Capacity Your Polaris snowmobile is designed for a single rider only. Do not carry a passenger. Survival Preparation For your safety, always ride in a group of other snowmobilers.
Operator Safety SAFETY Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: S Take an avalanche class S Travel with experienced people S Travel on designated trails S Make sure each person is equipped with a shovel, probe and avalanche beacon. You don’t have to be snowmobiling on a slope for an avalanche to occur. Be aware that all of the snow is connected.
SAFETY Operator Safety 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 laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead. Multiplying speed (MPH) by 1.5 will equal the approximate number of feet per second your machine travels. If your speed is 40 MPH, your machine is traveling about 60 feet per second.
Operator Safety SAFETY Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward.
SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do not operate the engine with the intake silencer or filter removed. Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches.
Operator Safety SAFETY Inadequate Snow Conditions WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your machine. Driving in too little snow will result in excessive wear and damage to the slide rail, track and/or engine.
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. WIND CHILL CHART (°F) Wind Speed in MPH Actual Thermometer Reading (°F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 -20 -34 -41 -45 -48 -51 -53 -55 -57 -58 -60 -61 -62 -25 -30 -40 -46 -47 -53 -51 -58 -55 -61 -58 -64 -60 -67 -62 -69 -64 -71 -65 -72 -67 -74 -68 -75 -69 -76 5 min.
SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
SAFETY Safety Decals and Locations Track Warning The track warning decal is located on the rear of the tunnel: + Passenger Warning This snowmobile is designed for one operator only.
SAFETY Safety Decals and Locations Operation Warning + 22
Safety Decals and Locations SAFETY Operation Warning 23
FEATURES AND CONTROLS 2 1 3 4 5 13 6 7 9 12 1. Brake Lever 14 2. Oil Light (600RR only) 3. Tachometer 4. Temperature Light 5. Engine Stop Switch 10 6. Throttle Control 7. Choke Control 8. Recoil Starter Handle 9. Fuel Filler Cap 11 10. Park Brake Lock 15 11. Headlight Dimmer Switch 12. Handlebar Grip Warmer/ Thumbwarmer Switch 13. Tether Switch 14. Master Cylinder 15.
FEATURES AND CONTROLS 1 2 11 10 3 4 5 9 8 7 6 1. 2. 3. 4. 5. 6. Handlebar Windshield Headlight Hood Nosepan Skis 7. 8. 9. 10. 11.
FEATURES AND CONTROLS Polaris DRAGON Ignition System (600 IQ Racer) 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.
FEATURES AND CONTROLS Polaris DRAGON Ignition System (600 IQ Racer) DRAGON Mode Operation 1. Warm up the engine and track. See page 54. 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. NOTE: The vehicle will launch forward at wide-open throttle.
FEATURES AND CONTROLS Electronic Reverse (PERCt) (600RR) Electronic reverse will activate only if the engine RPM is below 4000. If your machine is running at an altitude of over 6000 feet, adjust the ignition setting as described below. Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse. WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death.
FEATURES AND CONTROLS Electronic Reverse (PERCt) (600RR) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Push the reverse button for one second and release. The engine will slow and begin to rotate forward. The light on the tachometer will shut off. 3. Apply the throttle slowly to make sure the transmission is in forward. Altitude Setting At higher altitudes (above 6000 feet), the engine will require a different ignition setting to improve the success of the reverse system.
THE PERFECT FIT IQ 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 IQ Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 92 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spring is set is called spring preload. For the best ride, the spring preload should be set as low as possible to use the full travel of the ski shock, with occasional light bottoming.
THE PERFECT FIT IQ Front Suspension Adjustments Front 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. A = Low preload B = High preload Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the rear suspension.
THE PERFECT FIT IQ Front Suspension Adjustments Shock Valving Walker/Evans shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. WARNING Changing shock valving on Walker/Evans shocks 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 Rear Suspension Adjustments 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 excellent performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail.
THE PERFECT FIT IQ Rear Suspension Adjustments Rear 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. Contact your dealer for more information. 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.
THE PERFECT FIT IQ Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other. Rear suspension coupling links the movement of the front and rear torque arms to each other. There are two types of rear suspension coupling.
THE PERFECT FIT IQ Rear Suspension Adjustments Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front torque arm. Adjusting the RRSS either allows more weight to transfer to the rear for more traction, or allows less weight to transfer to the rear, resulting in improved cornering performance. An adjustment dot is located on the RRSS.
THE PERFECT FIT IQ Rear Suspension Adjustments Weight Transfer During Acceleration IQ Rear Rear Scissor Stop (RRSS) The preferred method for controlling weight 1 transfer during acceleration of the IQ rear suspension is by adjusting the RRSS. Use the scissor stop tool (1) located in your tool kit to make the adjustments. To decrease weight transfer under acceleration (for improved cornering), rotate the RRSS to a higher position.
Handlebar Adjustments THE PERFECT FIT Handlebar with Riser Block 1. Remove the handlebar cover to expose the handlebar mounting hardware. 2. Using a 1/4” Allen wrench, loosen the two bolts on the bottom of the riser or the two bolts on the top of the riser, depending on the type of adjustment required. 3. Adjust the handlebar to the desired angle.
THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. See your dealer for a complete list of accessories. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: Non-compliance with government/industry requirements Voiding of warranty S Personal injury to self or others S S This applies to, but is not limited to brakes, clutches, fuel systems, and exhaust systems.
Accessories THE PERFECT FIT Traction Products Another way to tailor your machine is to install traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance. NOTE: Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products.
THE PERFECT FIT Accessories CAUTION Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage. Center of stud must be at least 1 1/8″ (2.86 cm) from outside edge of the track. CAUTION If traction products are added to the track, wear strips must be installed in the tunnel to avoid excessive wear. Never add shims to the wear strip.
THE PERFECT FIT Accessories Wear Strips Polaris IQ models are manufactured with tunnel wear strips or wear strip coolers installed. To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Wear strips are designed for a specific stud length. See your dealer’s studding chart for recommended traction accessories. Components as viewed from the rear of the track: 1. Top of tunnel 2. Wear strip 3. Track 4.
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. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items.
PRE-RIDE INSPECTIONS Before Starting the Engine WARNING Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and refer to it often. We’ve attempted to provide as much information as possible to alert you to the safety requirements of snowmobiling.
PRE-RIDE INSPECTIONS Before Starting the Engine n Hydraulic Brakes Always check the following items to assure proper operation before starting the engine. 1/2″ (1.3 cm) 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 80. Lever Feel If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition.
PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Your snowmobile may have a parking brake lever lock located over the brake lever. 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. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reservoir / Cover 2 3 1 Lock Engagement To engage the lock, squeeze the brake lever tightly and push forward on the lock.
PRE-RIDE INSPECTIONS Before Starting the Engine n Check for Proper Operation of Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable components are properly lubricated. n Track Inspection WARNING Always inspect the track for damage before using the vehicle.
PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Before Starting the Engine beginning on page 45. n 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 Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Always premix the initial fuel and future fuel as outlined in the tables on page 51. CAUTION 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 Engine Break-In Fuel Recommendations CAUTION Using fuels with a lower than recommended octane or operating with obstructed fuel systems will result in serious and costly engine damage. Always use the recommended fuels for your machine. 600 IQ Racer Fuel Always use premium non-oxygenated (92 octane) fuel. 600RR Fuel Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease.
OPERATION Engine Break-In Fuel Recommendations WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not overfill the tank. Do not fill the tank neck. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Starting the Engine OPERATION Starting a Cold Engine Do not depress the throttle until the engine starts. 1. Attach the tether cord to the tether switch. 2. Pull the kill switch (shut-off switch) up to RUN. 3. Flip the choke toggle to FULL CHOKE. 4. Grasp the starter handle and pull slowly until the recoil engages, then pull abruptly to start the engine. CAUTION Don’t pull the starter rope to full extended position or allow it to snap back into the housing. Damage may result.
OPERATION Engine and Track Warm-Up WARNING A loose track or flying debris could cause serious personal injury or death. Stand clear of the front of the machine 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.
Slide Rail and Track Cooling OPERATION CAUTION Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or roads. Injection Oil Level (600RR) The low oil indicator light will alert the operator if the oil level is low.
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.
n Engine Stop Switch Push down on the engine stop switch (1) to stop the engine in an emergency. To restart the engine, pull the switch up to the ON position. OPERATION 1 Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 57 for more information about the engine stop switch.
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″ (10 cm) off the ground. Cover the machine with an appropriate cover. Towing WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in serious injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a rope.
Emission Control Information MAINTENANCE 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 hangtag. 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 service checks outlined in this manual. Record services performed in the Maintenance Record at the rear of this manual. 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 P Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Periodic Maintenance Interval Table Item See Page P Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Periodic Maintenance Interval Table Item See Page P Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE Lubrication Lack of lubrication will adversely affect your ride and the life of components. Lubricate with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. A grease gun kit, complete with grease and adaptors, is available to lubricate all fittings on Polaris snowmobiles. See page 99 for the part numbers of Polaris products.
Lubrication MAINTENANCE Front Suspension Two components of the IQ front suspension and steering require lubrication. S Grease the left and right spindles. Raise the front end of the machine to permit better grease entry into the spindle area. S Lubricate the steering post U-joint. Throttle Cable Lubricate the throttle cable (1) lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown.
MAINTENANCE Lubrication n Chaincase Oil Level Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 60. To check the oil level, place the machine on a level surface. The oil level should be between the “safe” marks on the dipstick (A). Add Polaris synthetic chaincase oil through the dipstick opening. Do not overfill. See page 99 for the part numbers of Polaris products. Flush the chaincase after the first 500 miles, then every 1000 miles or seasonally.
Spark Plugs MAINTENANCE A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning. In selecting a spark plug heat range for production, a manufacturer assumes that the engine will be operated under extreme heavy duty conditions and selects a spark plug that will protect the engine from internal damage if the purchaser actually does operate the engine in this manner.
MAINTENANCE Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. WARNING A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing a spark plug for inspection. NOTE: Incorrect fuel mixture can often cause a spark plug to appear too dark or too light in color.
Intake Filter MAINTENANCE The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filters periodically to remove any accumulation of snow. CAUTION 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 Variable Exhaust System (VES) Maintenance of the VES is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles (800-1600 km), bring the machine to an authorized Polaris dealer to have the VES disassembled, inspected, and cleaned. NOTE: To ensure maximum performance and minimize required maintenance, follow the oil recommendations on page 50.
Carburetor MAINTENANCE The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It’s your dealer’s responsibility to make sure the correct main jet is installed. CAUTION Operating the snowmobile with incorrect jetting can result in serious engine damage. Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly.
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. WARNING Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running.
Engine Cooling MAINTENANCE Coolant Mixture The coolant supplied in the system is a 50/50 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing at temperatures to -34° F (-37° C). If greater protection is required, the percentage of antifreeze to water may be increased. Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture.
MAINTENANCE Engine Cooling Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine, the system should be completely drained every two years and a fresh 50/50 or 60/40 mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile. WARNING Steam and hot liquids will cause serious burns to your skin.
Engine Cooling MAINTENANCE Bleeding the Cooling System 3. Tip the snowmobile slightly onto its right side. Cycle the RPM from idle to enough RPM (4000) to get coolant to flow, but not enough to engage the clutch. This allows air to bleed from the rear crossover tube. NOTE: There must be enough coolant flow to purge the air from the crossover hose or rear cooler so you can observe this air reaching the bottle. 4.
MAINTENANCE Drive Chain Tension To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. Loosen the adjuster bolt jam nut (A). 3. Finger tighten the adjuster bolt (B) until it can no longer be adjusted by hand, then back off 1/4 turn. 4. Tighten the jam nut while holding the adjuster bolt. 5. The chain is now tensioned. Release the brake lever lock.
n Hydraulic Brake Inspection MAINTENANCE Frequently inspect the brake lever reserve. Squeeze the brake lever. It should move no closer to the handgrip than 1/2″ 1/2″ (1.3 cm) (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 80. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16″/1.6 mm). A kit is available for replacing brake pads. See your dealer.
MAINTENANCE Brakes Brake Components 1 2 5 4 3 1. 2. 3. 4. 5. Brake Caliper Chaincase Brake Disc Backing Plate Brake Pad Material (Replace when thickness is less than 1/16″). Excessive Brake Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, as described on page 77, the machine should be returned to an authorized Polaris dealer for inspection and adjustment.
Brakes MAINTENANCE 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 severe injury. WARNING 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 Headlights Headlight Adjustment 25’ (7.6 m) x x 2″ (5.1 cm) 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 (7.6m) 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.
MAINTENANCE Headlights NOTE: 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. Removing Halogen Bulbs - High/Low Beam 1. Pinch the ends of the spring (1) together and lift until it releases 2 from the spring retainer. 2. Lift spring carefully around wire harness (2) and flip to outside of housing. 3. With the wire harness attached 1 to the bulb (3), withdraw bulb from housing. 4.
Clutch System MAINTENANCE Periodically inspect the 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 n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare belt. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile. Drive Belt Removal CAUTION Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal.
Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4”. MAINTENANCE A B C Drive Belt Adjustment 1. Loosen the 7/6” jam nut on the belt width adjuster. 2. Using a 1/8” Allen wrench, adjust the threaded set screw (C) as needed.
MAINTENANCE Torque Stop If your snowmobile is equipped with an engine torque stop (1), periodically check torque stop clearance. With clutches in proper alignment, the torque stop clearance should be a minimum of .010″ to a maximum of .030″ from the engine case (2). Adjust if necessary, and lock the jam nut.
Chain Tension MAINTENANCE Maintain the proper chain tension as outlined on page 76. 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. Tool Kit A tool kit is included with each machine for emergency and routine maintenance. Always keep the tool kit with the snowmobile.
MAINTENANCE 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 Tension Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Tension adjustments should be made only after the track is warmed up and limber. 1. Turn the machine off. 2.
Track Maintenance MAINTENANCE If the track needs adjustment (continued): 8. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new. 9. Start the machine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brakes). 10. Check track alignment (see page 89) and adjust as necessary. 11. Tighten locknuts (A). 12. Tighten idler shaft bolts (D) and torque to 35 ft. lbs. (47.5 Nm).
MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods are a serious safety hazard. They can cause a rotating track to come off the machine, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. Using a hoist, safely lift and support the rear of the snowmobile off the ground. Rotate the track by hand to check for possible damage.
Steering System MAINTENANCE Steering Inspection and Adjustment Each week, or before a long ride, check all fasteners and tighten if necessary. Specifically check fasteners marked with a +.
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 camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.
Steering System n Ski Skags MAINTENANCE 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. Check skags weekly to maintain positive steering characteristics.
MAINTENANCE Suspension Maintenance n Rail Slide Wear Measure slide thickness at several points along the rail. Have your dealer replace the slide when it’s worn down to the top of the wear limit indicator groove (A). Do not operate the snowmobile if slide thickness measures less than 7/16″ (1.1 cm). 7/16″ (1.1 cm) A n Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time.
Extended Storage MAINTENANCE Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. 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 Engine and Carburetor Protection Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on precision engine parts during storage. Whenever the machine is stored for a period of more than 60 days,the engine must be fogged with fogging oil. Follow the engine fogging instructions provided on the can. See page 99. Always add Premium Carbon Clean or a fuel conditioner/stabilizer to the fuel tank.
Extended Storage MAINTENANCE Electrical Connections Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. See page 99 for the part numbers of Polaris products. 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.
MAINTENANCE Transporting the Snowmobile Whenever the snowmobile is transported: 1. Turn the fuel valve clockwise to OFF to shut off the fuel supply (1). Turn the valve counter-clockwise to ON to turn the fuel supply on (2). NOTE: 1 2 The fuel valve is located under the hood. 2. Be sure the fuel cap is installed correctly. 3. Always tie the snowmobile to the transporting unit securely using suitable straps.
POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2873023 Synthetic 2-Cycle Racing Oil (gal.) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (gal.) 2872347 Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.) 2874438 VES II Synthetic 2-Cycle Engine Oil (qt.
TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Erratic engine operating RPM during acceleration or load variations Probable Cause Drive clutch binding Driven clutch malfunction Solution -Disassemble drive clutch to inspect shift weights for wear and free operation. SEE YOUR DEALER. -Clean and polish stationary shaft hub. -Replace ramp buttons and rollers. SEE YOUR DEALER.
TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive system Probable Cause Broken drive clutch components -SEE YOUR DEALER. Bearing failure/ chaincase, jackshaft, or front drive shaft -SEE YOUR DEALER. Drive belt surface flat spots Poor low RPM performance Engine doesn’t turn Engine requires more than normal pulls to start Solution -Inspect and replace if necessary. Drive chain loose or worn, sprocket teeth broken -Inspect and adjust or replace.
TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Probable Cause Faulty ignition No fuel to engine Flooded engine (normal situation caused by too much choking) Solution -Remove spark plug(s) and replace with new plug(s). If engine still fails to start, check for spark; if no spark SEE YOUR DEALER. -Make sure the fuel valve is “ON”. Check tank level and fill up with correct fuel. -Ice in fuel line, filter, or pump.
TROUBLESHOOTING Suspension Troubleshooting Problem Solution (perform only one change at a time) Rear suspension bottoms too easily -Increase torsion spring preload -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 -Decrease torsion spring preload adjustments -Decrease rear shock compression valving by turning screw counterclockwise (if equi
TROUBLESHOOTING Belt Troubleshooting Belt Wear/Burn 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.
Service And Warranty Information WARRANTY 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.
WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty. The warranty begins on the date of purchase. This warranty is transferrable to another consumer, during the warranty period, through a Polaris dealer.
WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle PreDelivery Inspection, perform all applicable service bulletins and have the consumer sign the pre-delivery inspection (PDI) form prior to delivery may void the warranty. Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage.
WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transferable 120 days after the original purchase date, free of charge, through any Polaris snowmobile dealer.
WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions.
WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris standard limited warranty for snowmobiles. Polaris Industries Inc. warrants that the new engine, including all parts of its emissioncontrol system, is designed, built and equipped so it conforms to current U.S. Environmental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068 at the time of sale to the ultimate purchaser.
MAINTENANCE RECORD DATE MILES/KM 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS 113
MAINTENANCE RECORD DATE 114 MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS
INDEX A Accessories . . . . . . . . . . . . . . . . . . 40-43 Altitude Ignition Setting . . . . . . . . . . 29 Avalanches . . . . . . . . . . . . . . . . . . . . 13 B Before Starting the Engine . . . . . . 45-48 Belt Troubleshooting . . . . . . . . . . . 104 Bleeding the Cooling System . 67, 74-75 Bleeding the Brake System . . . . . . . . 80 Brake Components . . . . . . . . . . . . . . 78 Brake Fluid . . . . . . . . . . . . . . . . . . . . 79 Brake Lever Travel . . . . . . . . . . .
INDEX J Jetting Guidelines . . . . . . . . . . . . . . . 56 L Lighting Check . . . . . . . . . . . . . . . . . 49 Lubrication . . . . . . . . . . . . . . . . . . 64-66 M Maintenance Interval Table . . . . . . 61-63 Maintenance Program . . . . . . . . . . . . 60 Maneuverability . . . . . . . . . . . . . . . . 16 O Oil Filter . . . . . . . . . . . . . . . . . . . . . . 69 Oil Level, Injection (600RR) . . . . . . 55 Oil Lines . . . . . . . . . . . . . . . . . . . . . . 69 Oil Recommendations . . . . . .
