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Polaris 570 Offroad Vehicle User Manual

1. 92 SkiSkags 93 Slide Rail and Track Cooling 55 116 S Spark Plugs is eese pe Ies 67 68 Start the Engine and Check 49 Starting a Cold Engine 53 Starting a Warm Engine 53 Starting the Engine 53 Steering Adjustment 91 Steering Inspection 91 Steering System 48 91 93 SLOPPIN Gs sin lw Rc RE YAN ee 57 Storage s ee cee per he 58 95 97 SIOISBe set eee ca hae oe PI 96 Survival Preparation 12 Suspension 97 Suspension Coupling 36 Suspension Maintenance 94 Suspension Performance Tips 34 Suspension Troubleshooting 103 Suspension Front 30 33 Suspension 34 38 Symbols 7 T Tether Switch 49 Throttle Cable 65 Tool Kit else neg 87 Torque Stop 86 Torsion Spring Tension 35 Towing os ic chee c em erem 58 Frack 97 Track 89 Track 55 Track Inspection 48 90 Track Lubrication 90 Track Maintenance 88 90 Track Safety 10 Track Tension 88 Track Tension Data 88 Track Warm Up 54 Track Warning 21 Traction Products 41 Transporting the Snowm
2. 22 SAFETY Safety Decals and Locations Operation Warning AVERTISSEMENT Pour viter des blessures graves ou mortelles lire et veiller bien comprendre tous les avertissements ainsi que le manuel d utilisation avant d utiliser la machine Si le manuel est manquant contacter un concessionnaire Polaris pour obtenir un exemplaire de rechange Ce v hicule peut atteindre des vitesses lev es Des objets enterr s ou les in galit s du terrain peuvent causer une perte de contr le Ralentir et faire preuve de la plus grande prudence lors de la conduite sur terrains accident s Une vitesse excessive particuli rement la nuit ou lorsque la visibilit est r duite peut ne pas laisser le temps de r agir en pr sence d un terrain accident d viter un obstacle ou d arr ter en toute s curit Ne jamais consommer d alcool ou de drogue avant ou pendant la conduite de ce v hicule En cas d urgence appuyer sur le M bouton d arr t auxiliaire se trouvant sur le dessus de l ensemble de commande des gaz pour arr ter le moteur Ensuite tirer le levier de frein v immobiliser le v hicule Toujours porter un casque homologu des lunettes de protection et les v tements appropri s pendant la conduite de ce v hicule Ce v hicule est con u pour tre utilis par des adultes exclusivement Consulter les r glementations locales concernant les limites d ge Lors du
3. 4 WARNING 4 AVERTISSEMENT DO NOT OPERATE ENGINE WITH HOOD OPEN N OP REZ PAS LE MOTEUR LORSQUE LE CAPOT EST OUVERT DO NOT ATTEMPT ADJUSTMENT WITH ENGINE RUNNING N EFFECTUEZ AUCUN AJUSTEMENT LORSQUE LE MOTEUR EST EN MARCHE _ DO NOT OPERATE ENGINE WITH THIS GUARD OPEN NE FAITES PAS FONCTIONNER LE MOTEUR LORSQUE CE GARDE DE S CURIT EST OUVERT NEVER RUN ENGINE WITH DRIVE BELT REMOVED NE JAMAIS LAISSER LE MOTEUR EN MARCHE LORSQUE LA COURROIE D ENTRAINEMENT NEVER SERVICE CLUTCHES YOURSELF SEE YOUR DEALER EST ENLEVEE NE R PAREZ JAMAIS L EMBRAYAGE VOUS MEMES VOIR VOTRE CONCESSIONNAIRE 7075350 Pressure Cap Warning This warning decal is found on the coolant REPLACE UMEN bottle cover of liquid cooled models CODEANT PRESS DOUIN amp TURN TORELEASE Reverse Warning if equipped QUU The reverse warning decal is located on the console either beside the steering post or below the windshield on equipped models WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Machine stopped and engine at idle push red button on LH control to reverse Flashing light on dash indicates reverse operation Push button again
4. Slow easy clutch en Use fast aggressive throttle to engage clutch gagement 104 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 When contacting us about parts service or warranty always provide the following information 1 Serial number 5 Details of trouble experienced 2 Model number 6 Length of time and conditions of operation 3 Dealer name 7 Previous correspondence 4 Date of purchase Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris Customer Service United States 1 888 704 5290 Canada 1 204 925 7100 Polaris Anti Theft System The Polaris anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines Administration 1 Polaris snowmobile owner reports theft A In addition to notifying the proper law enforcement offi cials the owner must call Polaris Customer Service B Owners must provid
5. Grasp the starter handle and pull slowly until the recoil engages then pull abruptly to start the engine amp CAUTION Don t pull the starter rope to full extended position or allow it to snap back into the housing Damage may result To avoid personal injury and or engine damage do not operate the recoil pull rope starter while the engine is running 5 After the engine starts flip the choke toggle to the OFF position If the engine slows or wants to stop use intermittent choking to the HALF CHOKE position 6 Warm up the engine before operating See page 54 Starting a Warm Engine 1 Attach the tether cord to the tether switch 2 Pull the kill switch shut off switch up to RUN 3 Grasp the starter handle and pull slowly until the recoil engages then pull abruptly to start the engine If the engine does not start on the first pull slightly depress the throttle with your left hand no more than 1 4 open and pull the rope with your right hand When the engine starts immediately release the throttle 53 OPERATION Engine and Track Warm Up amp WARNING Follow these steps to ensure proper warm up of the engine drive train and track 1 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
6. Increase front track spring preload Reduce IFS spring preload by adjusting cam Reduce rear torsion spring preload Change worn rail slide Move front track shock assembly to upper position 103 TROUBLESHOOTING Belt Troubleshooting Belt Wear Burn Belt Wear Burn Diagnosis 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 Riding with high RPM Lower the gear ratio Remove windage plates from the and slow speed 8000 clutch Reduce RPM Avoid riding in high ambient RPM 10 MPH temperatures Ice and snow build up Warm the engine at least five minutes Take the drive belt off between track and the machine in extremely cold weather and warm it up tunnel Break machine loose from the snow Poor engine Check for carb and choke synchronization fouled plugs performance debris in the carbs and water ice or dirt in gas tank or fuel line Loading machines onto Skis may gouge into trailers and prevent the drivetrain from trailers spinning properly Use enough speed to drive the machine completely onto the trailer Push and pull it to finish loading if necessary Clutch malfunction Inspect clutch components See your dealer
7. Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter machines we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly Air Pollution Polaris engineers continuously investigate ways to reduce emission levels of two stroke engines We expect our efforts to lead to the reduction of potential air pollution In addition to our technological research we encourage government agencies manufacturers distributors dealers ecologists and other interested parties to work together to develop data on environmental topics INTRODUCTION Vehicle Identification Numbers Record your snowmobile s identification numbers in the spaces provided Vehicle Model Number Tunnel VIN lower right side of the tunnel Engine Serial Number right front side of engine crankcase 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 on your vehicle or in this manual alerts you to the potential
8. Change plug s Dirt or ice in fuel system Deicer should be added to non ethanol fuel at all times for assurance against fuel line icing Suspension Problem Rear suspension bottoms too easily Rides too stiff in rear Machine darts from side to side Front end pushes Steering is heavy Setting up for deep snow operation TROUBLESHOOTING Troubleshooting Solution perform only one change at a time Increase torsion spring preload Increase rear shock compression damping by turning screw clockwise Increase torsion spring wire diameter see your dealer 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 equipped with optional Indy Select shock Change to lighter valving if if equipped with Fox shocks Check for proper track tension Make sure skis are aligned properly Make sure spindles and all steering components are free turning Make sure skags are straight on skis Check rail slide and replace if worn Reduce ski pressure Reduce IFS spring preload Reduce rear torsion spring preload Check for worn skags Check for binding suspension shafts and grease all pivot points Increase IFS spring preload by adjusting cam or threaded ad juster Decrease front limiter strap length Check ski alignment Check skags and skis for damage Reduce ski pressure
9. Shocks contain high pressure nitrogen gas Use extreme caution when handling high pressure service equipment We recommend that this work be performed by a Polaris dealer Front Springs For models without externally adjustable or revalvable shocks the front springs can be changed if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness See your Polaris dealer for more information 33 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 A suspension set up for trail riding would bottom out harshly on a snow cross course A decal outlining rear suspension set up options is located either under the hood or on the clutch cover It provides a guideline for initial suspension set up Additional adjustments can be made from this point Make adjustments to one area at a time so you can evaluate the change For further assistance see your dealer Suspension Performance Tips e Rider weight usually determines the position at which the spring pre load should be set However this may vary with ridin
10. a 47 79 Fuel Management Piotarserews J Carburetor synchronize 1 1 1 1 fasrem o momet e 2 1 it synchronize t t 1 mecme t I vems FmowePostonSemor 1 1 _ a _ Fus 7 1 1 4 4 ome a a 1 fortines oorry a _ a eh spese ed mama WaerTas 7 _ raay Sron swin 9 T 1 1 1 4 Bam 3 mew 1 13 1 1 62 MAINTENANCE Periodic Maintenance Interval Table Ses Page 150mi 500 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season Chassis wmeagme 1 Suspension erena OC rtr SteeringFasteners 1 Rear Suspension o See Suspension Shockow CooingFins and Shroud Ses warsa L zer Post Support Bracket Drive Chain Tenson 76 moasa 46 1 Rear wneer aer Bois 1 Bok vamNut 1 camber Aignment Radius Roa Bushinss HandiebarGenterng 49 1 T
11. 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 Oil Lines 600 RR Inspect oil line condition every 1000 miles 1600 km Oil Filter 600 RR The oil filter is located at the side of the oil tank Have your dealer change the oil filter and bleed the system annually or every 1000 miles 1600 km The direction of the arrows indicates the direction of flow through the filter 69 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 Toensure maximum performance and minimize required maintenance follow the oil recommendations on page 50 The use of other lubricants may cause improper function of the valve mechanism and increase the frequency of required cleaning due to excessive build up of carbon deposits Fuel Pump fuel pump service must be performed by an authorized Polaris dealer Do not attempt to service the fuel pump Fuel Filter Fuel Lines See your Polaris dealer for replacement of the in tank fuel filter every 10
12. stays open NOTE Asthe thermostat draws in cold coolant from the heat exchangers the cold coolant may close the thermostat Make sure it opens and stays open 74 MAINTENANCE Engine Cooling 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 Tilt the machine slightly onto its left side so that the coolant bottle is the highest point in the cooling system Cycle the RPM as outlined in step 3 NOTE There must be enough coolant flow to purge the air from the front close off cooler so you can observe the air reaching the bottle 5 Return the snowmobile to its upright position and loosen the bleed screw at the top of the water outlet manifold When all trapped air has been purged tighten the screw 6 Turn off the engine and release the parking brake Allow the system to cool completely NOTE After cool down three 3 or more ounces of coolant may have to be added 7 Remove the pressure cap and check the coolant level Add coolant to the fill line if necessary 75 MAINTENANCE Drive Chain Tension To obtain correct chain tension 1 Rotate the driven clutch counterclockwise to m
13. 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 78 MAINTENANCE Brakes Brake Fluid amp 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 4 WARNING Keep the master cylinder cover free of dirt and debris The vent slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function CAUTION Brake fluid will damage decals paint and some plastics Always wipe up spills immediately Maintain the brake fluid level between the MIN and MAX marks on the master cylinder reservoir Use only Polaris DOT 4 high temperature brake fluid See page 99 for the part numbers of Polaris products 79 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 amp WARNING Operating the ve
14. 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 Contact you dealer if greater protection is required NOTE Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system Coolant High Temperature Indicator Light The high temperature indicator light is controlled by a switch in the engine cooling system on liquid cooled models If the engine coolant reaches a certain temperature the switch completes a circuit that turns the light on 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 See your dealer Coolant Level Maintain the coolant level at the full cold line on the coolant bottle when the engine is cold CAUTION Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recommended The engine coolant level is controlled by the recovery system The recovery system componen
15. OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEG LIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclu sion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 106 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES 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 How to Obtain Warranty Service If your snowmobile requires warranty service you must take it to a Polaris dealer autho rized to repair Polaris snowmobiles 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 recommends that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate p
16. Operator Safety Inadequate Snow Conditions amp 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 If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the throttle is opened the snowmobile will be able to climb up and over the snow amp CAUTION When operating on icy surfaces or hard packed snow avoid overheating the slide rail and track Lack of lubrication and cooling will cause overheating of the slide rail and track resulting in premature wear and failure If frequently operating in low cooling conditions see your dealer for an optional wheel kit that will reduce the wear from overheating 17 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 fo
17. for injury 4 amp WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death amp CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions 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 amp 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 Use extra caution to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aerodynamically unstable at speeds higher than th
18. lubricate clutch components except the driven clutch shaft bushing as outlined in the Master Repair Manual See your dealer 95 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 See page 99 for the part numbers of Polaris products Follow the instructions on the can running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel premixed for 600 IO Racer If stabilizer is not used drain the carburetors by removing the water trap drain plugs See page 71 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 4 Rotate the engine slowly watching the piston until it s at bottom de
19. or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above you
20. or improper handling main tenance or use This limited warranty also does not cover any engine that has been structurally altered This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polar is Owners are responsible for performing the scheduled maintenance identified in the own er s manual Polaris can deny an emissions warranty claim if any specified critical emis sions related maintenance is not performed Performance of other scheduled maintenance is strongly recommended but is not necessary to keep the emissions related warranty valid Any qualified repair shop or qualified person may maintain replace or repair the emission control devices or systems on your snowmobile Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law and may result in civil penalties 111 MAINTENANCE RECORD 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 8200 km 112 MAINTENANCE RECORD 113 MAINTENANCE RECORD 114 A Accessories 40 43 Altitude Ignition Setting 29 Avalanches 13 B
21. 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 Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses sponsored by local or state organizations 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 You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding clubs 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 Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that snowmobiles conform to prescribed sound levels
22. 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 To set for a higher altitude start the engine and hold the button down until the light on the tachometer flashes rapidly then release the button To set the reverse for lower elevations continue holding the button down until the reverse indicator light blinks slowly Once set it s stored in memory until changed whether the engine is running or not Reverse Kit Maintenance If your snowmobile is equipped with reverse or if you have a reverse kit installed it s especially important to maintain track tension as specified on page 88 amp WARNING Improper track tension can cause serious damage to the snowmobile which can result in loss of vehicle control and serious injury or death Always maintain the track tension as specified 29 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
23. 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 This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the snowmobile Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper The track should be approximately 4 10 cm off the ground Ses Start the engine and allow it to warm up two x to three minutes Depress the throttle abruptly and allow the track to rotate several revolutions NOTE Itwill take longer to warm up the track sufficiently during colder 4 5 54 outdoor temperatures Release the throttle apply the brakes shut off the engine and lower the machine to the ground Grasp the skis by their front loops and move them from side to side This will loosen frozen snow from the ski bottoms allowing the machine to move forward more easily The engine drive system and track are now properly warmed up and the machine may be driven following normal safety practices OPERATION Slide Rail and Track Cooling 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 surf
24. to return to forward 20 SAFETY Safety Decals and Locations Track Warning The track warning decal is located on the rear of the tunnel A WARNING AVERTISSEMENT Stay clear of track Do not sit on Demeurer l cart de la chenille Ne seat back Entanglement with the pas s asseoir sur le dossier du si ge track or a fall from seat back can Tout contact avec la chenille ou une result in severe injury or death chute du dossier peut causer des 7172519 blessures graves ou la 7172520 Passenger Warning This snowmobile is designed for one operator only A No Passenger warning decal is located on the lower console AX WARNING AVERTISSEMENT This vehicle is designed for operator only NO PASSENGER Ce v hicule est concu pour ne transporter que le conducteur AUCUN PASSAGER 7172676 21 SAFETY Safety Decals and Locations Operation Warning A 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 Excessive speed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes to avoid unexpected o
25. to the ECU box coils stator plate and sensors Wiring and other electrical components are excluded from coverage Cooling system coverage is limited to the water pump assembly and components fan fan bearings temperature sensor gasket and seals Non wear related throttle body parts are covered The fuel pump is covered e Clutches and related clutch parts including but not limited to the drive belt are ex cluded from coverage Electrical components are excluded from coverage e Gearcases and transmissions are excluded from coverage 109 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION 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 This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move
26. 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 2 3 4 Top of tunnel Wear strip Track Wearstrip mounting holes 1 CAUTION Whenever wear strips are relocated be sure there s adequate stud clearance to the heat exchangers Lack of clearance may result in damage to heat exchangers 43 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 on the referenced pages to locate the pre ride inspection items mem Seems Drive Belt Condition Steering System Recoil Rope Coolant Level Suspension MouningBols Skags Wear Bars Hood Straps Latches Seat Latches if equipped Throttle Lever Rear Wheel Idler Bolts Tether Switch Strap Track Alignment Condition Rail Slide Condition Chaincase Oil Level Injection Oil Level 600RR 44 PRE RIDE INSPECTIONS Before Starting the Engine amp WARNING Worn damaged or malfunctioning components may cause serious injury or death Before starting the engine
27. 00 miles 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 CAUTION Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly 70 MAINTENANCE Carburetor 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 Carburetor Adjustments The frequency at which the carburetors are synchronized or balanced is important Properly adjusted carburetors can greatly improve engine performance fuel economy engine life and reliability If you notice any of the following conditions the carburetor may need adjustment e Hard starting Poor idle e Overheated pistons and cylinder walls Plug fouling Poor engine response to various throttle valve openings Carburetor Water Sediment Trap Drain the water sediment traps located at the b
28. 23 2871098 2871097 2871240 2871721 2871722 2872347 2874438 2874439 2874443 Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz 2871312 2871322 2871423 2871329 2871323 Anitfreeze 60 40 Premix gal 2871534 Anitfreeze 60 40 Premix qt 99 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 accelera tion or load variations Harsh drive clutch engagement Drive belt turns over Machine fails to move 100 Probable Cause Drive clutch binding Driven clutch malfunction Drive belt worn or too narrow Excessive belt sheave clearance Wrong belt for application Clutch alignment out of spec Engine mount broken or loose Clutch jammed Track jammed Chaincase sprocket or chain jammed or bro ken 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 Inspect movable sheaves for excessive bushing clearance and replace if necessary SEE YOUR DEALER Replace drive belt SEE YOUR DEALER Replace drive belt Adjust alignment offset Inspect and adjust or replace SEE YOUR DEALER Belt twisted spring br
29. 30 Intake 69 Intake Silencer 16 INDEX J Jetting Guidelines 56 L Lighting Check 49 Lubrication 64 66 M Maintenance Interval Table 61 63 Maintenance Program 60 Maneuverability 16 69 Oil Level Injection 600RR 55 Oil Eines rep Sonate etd 69 Oil Recommendations 50 Operating Area 49 Operation Warning 22 23 Operator 5 7 19 P Passenger Warning 21 Polaris Products 99 Pre Ride Checklist 44 Pre Ride Suspension Inspection 94 Pressure Cap Warning 20 R Rail Slide Wear 94 Rear Rear Scissor Stop 37 Recommended Maintenance Program 60 R VetSe 22 2 ere EE 28 29 Reverse Kit Maintenance 29 Reverse 20 Rider Capacity 12 Riding Apparel 9 Riding Position 10 S Safety Decals and Locations 20 23 Scissor Stop 36 37 Service and Warranty Information 105 Shock Absorber Components 31 Shock Damping 32 Shock Spring Preload Front 32 Shock 33 Signal words 7 Skag Replacement 93 Ski
30. ARNING If the parking brake lever lock is partially or entirely engaged while riding the brakes may overheat resulting in brake damage In extreme cases it could cause a fire which could result in serious injury or death Always ensure that the lever lock is completely disengaged before operating the snowmobile 47 PRE RIDE INSPECTIONS Before Starting the Engine 1 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 Track Inspection 4 WARNING Always inspect the track for damage before using the vehicle Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty Check Hood Latches The hood of the snowmobil
31. 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 46 78 Brake Parking 47 iid ble vue Re 78 80 Brakes Hydraulic 46 C Carburetion 56 71 Carburetor Adjustments 71 Chain Tension 87 Chaincase Oil Level 66 Choke and 65 Cleaning and Preservation 95 Clutch Alignment 83 Clutch and Drive System 95 Clutch Center Distance 83 85 Clutch Cover Warning 20 Clutch 83 85 Clutches aoina re 0 0 0 eee eee 16 Cold Weather Drive Away 16 Controls and Linkage 95 Coolant 73 Coolant Mixture 73 Cooling 2e eve aise 72 75 D Daily Storage 58 Disabled Operators 12 DRAGON Ignition System 26 27 DRAGON Mode Facts 26 DRAGON Mode Operation 27 Dnye Belt 16 Drive Belt Adjustment 85 Drive Belt Condition 84 Drive Belt Deflection 85 Drive Belt Installation 84 Drive Belt Removal 84 Drive Chain Te
32. 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 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 2 Apply the brake or lock the parking brake if equipped 3 Open the hood remove the clutch guard retaining pin and open the clutch guard 4 Rotate the driven clutch counterclockwise 1 4 turn by hand to ensure forward engagement 5 Locate the L wrench in the tool kit and install it into the open threaded hole in the outer sheave of the clutch Rotate the wrench until the sheaves open far enough to remove the belt Drive Belt Installation 1 Drop the drive belt over the drive clutch and pull back the slack A NOTE Toensure satisfactory belt life install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt removal procedures 2 Rotate the L wrench to tighten the sheaves Remove the wrench and store in the tool kit 3 Close the clutch guard and reinstall the retaining pin 4 Close and secure the hood and release the parking brake 84 MAINTENANCE Clutch System Drive Belt Deflecti
33. NING Improper riding position may reduce control and could result in serious injury or death Always be properly seated and in position to control your vehicle 10 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 The noise of your machine will drown out the sound of approaching vehicles Look ahead behind and to both sides before turning or crossing railroad tracks or highways Steep embankments may also hide your view Always leave yourself a way Variances in snow depth and or water currents may result in uneven ice thickness Always check with local residents or authorities for general information on conditions when traveling on lakes and streams that are strange to you Before riding your machine on a frozen body of water be sure the ice is thick enough to support the machine and its operator as well as the force created by a moving vehicle You may drown if you and the snowmobile break through the ice When teaching inexperienced operators to ride set up a predetermined course for practice Make sure they know how to drive
34. Pantone 426C POLARIS The Way Out Pantone 426C For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9921089 Rev 01 Printed in USA A 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 A 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 Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Po
35. RR only Tachometer Temperature Light Engine Stop Switch Throttle Control Choke Control Recoil Starter Handle Fuel Filler Cap 10 Park Brake Lock 11 Headlight Dimmer Switch 12 Handlebar Grip Warmer Thumbwarmer Switch 13 Tether Switch 14 Master Cylinder 15 Dragon Ignition System Switch 600 IO Racer or Electronic Reverse Button 600RR SO 00 cM pv enm 24 og FEATURES AND CONTROLS Handlebar 7 Track Windshield 8 Suspension Headlight 9 Snow Flap Hood 10 Taillights Nosepan 11 Seat Skis 25 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 amp 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 Read the Owner s Manual Always follow all instructions and warnings DRAGON Mode Facts The DRAGON Ignition System is intended for competition use on closed courses by experienced riders only There is no benefit to using DRAGON mode for normal trail riding Unnecessary extended or excessive use of DRAGON mode can re sult in severe engi
36. Spring Preload Adjuster Nut 6 Reservoir 4 5 NT 31 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 Decreasing the spring preload too much may allow the upper spring retainer to fall off NOTE Always leave at least one thread showing above the nut 1 Grasp the spring and turn it to the left to increase preload 2 Turn the spring to the right to decrease preload Shock Damping Walker Evans Shock Turn the adjuster 1 clockwise to increase stiffness Turn the adjuster counterclockwise to decrease stiffness 32 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 amp 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
37. aces 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 Visually check for oil in the tank bottle Add oil before further operation of the snowmobile See page 50 for oil recommendations Maintaining the proper oil level will prevent system aeration and possible loss of pumping action which could result in engine damage This is especially important when the machine is operated in mountainous terrain CAUTION Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refueling Add oil as needed Always maintain a visible level of oil in the tank If oil is not visible continued operation may cause serious engine damage See page 50 for oil recommendations The Polaris oil cap on the oil bottle is vented to allow proper oil flow See your Polaris dealer for recommended replacement parts 55 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 u
38. ad center BDC the lowest position in the cylinder On twin cylinder models the opposite piston will be up 5 Pour approximately two ounces of Polaris injection oil into the spark plug hole 6 Wait one to two minutes and perform steps 3 to 5 on remaining cylinders 7 Replace the spark plugs and lower the machine to the floor 96 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 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 Track and Suspension Moderate track tension should be maintained during summer storage The machine should be supported off the ground to allow the track to hang freely 97 MAINTENANCE Transporting the Snowmobile Whenever the snowmobile is transported 1 Turn the fuel valve 1 2 clockwise to OFF to shut 5 off the fuel supply 1 Turn the valve counter clockwise to ON to turn the fuel supply on 2 NOTE The fuel valve is located under the hood 2 Besure the fuel cap is installed correctly 3 Always tie the snowmobile to the transporting unit securely using suitable straps 98 POLARIS PRODUCTS Part No Description 2870791 28730
39. age under this engine service contract can be given Used snowmobiles are not eligible under this program e Snowmobiles used for commercial purposes or for racing are excluded from cover age Coverage Coverage for second year engine failures due to defects in materials and workmanship will be determined by Polaris in its sole discretion Coverage is automatic with no additional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validate this warranty A partial list of items excluded from coverage includes Damage due to accident fire explosion theft or other causes beyond Polaris control Damage caused by the failure of other components of the snowmobile Failures caused by improper fuel or oil Piston seizures unless caused by a defective engine component Failures caused due to improper adjustments Failure due to unauthorized service Failures due to lack of service as required in the owner s manual or Polaris updates This includes off season storage as listed in the owner s manual Failure due to use of unauthorized parts or modifications Normal wear parts including but not limited to spark plugs hoses batteries controls and recoil ropes are excluded from coverage Gaskets are covered as are intake and exhaust manifolds excluding paint coverage Electrical coverage is limited
40. aintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles 240 km 500 miles 800 km and 1000 miles 1600 km These inspections should be performed by a qualified service technician For continued optimum performance and component life continue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registered owner during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to service or adjust your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfortable performing these tasks yourself contact an authorized Polaris dealer for service CAUTION Hot components can cause damage to plastic Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection 60 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 Pola
41. al damage if the purchaser actually does operate the engine in this manner This selection could cause the customer who normally operates the engine under medium or light duty to have spark plug failure Refer to your Owner s Manual Supplement for the specific spark plug to be used in your machine CAUTION A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile See your Owner s Manual Supplement 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 Refer to your Owner s Manual Supplement for specific information Spark plug torque is 18 22 ft Ibs 24 30 Nm e Always carry spare spark plugs in case of an emergency CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs 67 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 amp WARNING A hot exhaust system and engine can cause serious burns Wear protecti
42. and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses sponsored by local or state organizations 11 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 Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the conditions you may encounter Such equipment may include but is not limited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cellular telephone For added protection carry the following items on your snowmobile at all times Spare Drive Belt Extra Set of Spark Plugs Tow Rope Extra Oil Fuel Deicer Winter Survival Kit rail Map Owner s Manual First Aid Kit 12 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipp
43. bile engine s emissions To the extent they are present on your snowmobile engine this includes electronic controls fuel injection com ponents exhaust gas recirculation system components and aftertreatment system compo nents Replacing or repairing other components not covered by this warranty is the responsibility of the snowmobile owner 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 POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WAR RANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS 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 if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limit ed warranty does not cover damage due to accidents abuse
44. bstacles or to stop safely Never consume alcohol or drugs before or while operating this vehicle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control the vehicle When operating on hard packed snow ice or when crossing roads steering and braking ability are greatly reduced Reduce speed and allow extra space to turn or stop x To maintain vehicle control on ice or hard packed surfaces you NS should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for long periods Do not leave brake engaged for more than five minutes Before starting engine check throttle brake and steering for proper operation Make sure hood is latched Be seated and in position to control the vehicle Oil injection system Use unmixed fuel only Check oil level when refueling
45. 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 Check Throttle and Brake for Proper Operation The throttle and brake are the primary controls of your snowmobile If either should malfunction loss of control could result Make sure the throttle lever compresses evenly and smoothly The lever should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly DO NOT start the engine Have the throttle serviced immediately The need for a properly functioning brake is critical Your snowmobile is equipped with the highest quality brake system available Check the brakes for correct operation before starting the engine 45 PRE RIDE INSPECTIONS Before Starting the Engine Hydraulic Brakes Always check the following items to assure 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 80 Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 79 C
46. creased wear to the brake pads will result from increased braking Extended wear brake pad kits are available See your dealer for more information 41 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 Track damage will result because of lack of clearance between upper carrier wheels and track Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tunnel 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 4 WARNING 42 Loss of control can result in serious personal injury or death Proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard packed snow or ice See your dealer for assistance THE PERFECT FIT Accessories Wear Strips Polaris IQ models are manufactured with tunnel wear strips or
47. e tow hitch on the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in the towed object Braking distances increase when towing loads Slow down to maintain control of the snowmobile If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damage to the steering components Remove the drive belt before towing and have a rider on the towed snowmobile to operate the brake and steering when necessary 58 CAUTION Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 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 hangtag These items are required by U S Environmental Protection Agency regulations The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover The ECI lab
48. e 106 for the part numbers of Polaris products NOTE When using oxygenated fuel containing ethanol additional alcohol deicers or water absorbing additives should not be used 51 OPERATION Engine Break In Fuel Recommendations amp WARNING 52 Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area 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 If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of conscious ness or death in a short time e Turn the fuel valve off whenever the snowmobile is stored or parked WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas OPERATION Starting the Engine 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
49. e page 89 for torque specs Check front torque arm limiter strap condition Check rail slide condition have your dealer replace when worn to minimum thickness Check track tension beginning on page 88 Lubricate grease all suspension components see page 64 NNN VY Check ski runner skag condition 94 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 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 Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint The machine should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components Controls and Linkage bushings spindle shafts tie rod ends and cables should receive a light coat of oil or grease Clutch and Drive System Remove the drive belt and store in a cool dry location Lubricate the sheave faces of the drive and driven clutches with a light coat of oil or Polaris Cable Lubricant See page 99 for part numbers Do not
50. e 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 Check Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear is found see your Polaris dealer for replacement 48 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 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 Tether Switch Make sure the engine shuts off when the tether is removed from the switch Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the machine 49 OPERATION Engine Break In No single action on your part is as important to long tro
51. e their name address telephone num ber and the model and serial number of stolen machines 2 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 Polaris warranty will aid in notifying the proper owner when a unit is recovered 105 WARRANTY Limited Warranty Polaris Sales Inc 2100 Highway 55 Medina MN 55340 provides a ONE YEAR LIM ITED 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 war ranty period through a Polaris dealer Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS Initial dealer preparation and setup of your snowmobile is very important in ensurin
52. ed before traveling in mountainous terrain Take an avalanche class e Travel with experienced people Travel on designated trails e 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 You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in mountainous terrain Before riding in mountainous terrain call or log on to your local avalanche advisory to get current weather and snow stability information For more information about avalanche training and avalanche conditions contact local law enforcement in your area or visit the American and Canadian online avalanche centers at www avalanche org Ice and Snow Build up 4 WARNING Ice and snow build up may interfere with the steering of your machine 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 13 SAFETY Operator Safety Excessive Speed amp WARNING High speed driving especially at
53. el should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 91 R M 2 for the 600 IO Racer and 87 2 for the 600RR The emission control system designation per SAE J1930 is EM If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is available to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owner s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty on page 111 and read the maintenance section of your owner s manual You are responsible for ensuring that the specified maintenance is performed Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary 59 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 m
54. ersonnel at Polaris if additional assistance is needed This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 107 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 Pre Delivery 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 Use of the recommended Polaris products for lubrication and mainte nance as directed by the Owner s manual is highly recommended Should a failure occur during the warranty period resulting from the use of non recommended products war ranty coverage may be denied Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination The following items are excluded from warranty con s
55. es from oil added to the fuel and oil injection systems Always check and fill the oil tank when refueling See page 55 CAUTION Serious engine damage can occur without the proper lubrication Check the oil tank level often during the first tank of fuel If the oil level doesn t go down contact your dealer immediately 50 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 Do not use lower than 87 octane fuel Do not use fuel containing more than 10 ethanol including E85 Fuel Premix Initial Tankful of Fuel 600 IQ Racer 3 5 gal 13 2 I 16 oz 473 ml 600RR 5 gal 19 I 16 oz 473 ml 600 IQ Racer 3 5 gal 13 2 I 14 oz 414 ml 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 Plus See pag
56. fter adjustments are complete tighten locknuts and torque idler shaft bolts to 35 ft 165 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment 89 MAINTENANCE Track Maintenance Track Inspection amp 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 21 3 12 rear of the snowmobile off the ground Rotate the track by hand to check for possible damage Carefully examine the track along the entire length of each rod bending the track and inspecting for breakage The three most common damage areas are shown in the illustration Replace the track if any rod damage is found Track Lubrication amp 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 Avoid operating for extended periods on ice and other surfaces that have little or no snow for lubrication The slide rail requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear NOTE If excessive slide wear
57. g trouble free operation Purchasing a snowmobile in the crate or without proper dealer setup will void your warranty coverage Warranty Coverage and Exclusions Limitations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for purposes other than for which it was manufactured The warranty does not cover any damages that oc cur during trailer transit or as a result of unauthorized service or parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or punc turing of upholstery material corrosion or defects in parts components or the snowmo bile due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the snowmobile The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REM EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL
58. g condition Tool Kit A tool kit is included with each machine for emergency and routine maintenance Always keep the tool kit with the snowmobile NOTE Thetools and maintenance items mentioned in this book as well as a long line of other Polaris accessories are available at your Polaris dealer 87 MAINTENANCE Track Maintenance amp 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 Liftthe rear of the machine and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see Track Tension Data below ahead of the center of the rear idler wheel NOTE Measure at the point where the weight is hanging 4 Check for specified slack between the wear surface of the track clip and the plastic slider C If the track needs adjustment 5 Loosen rear idler shaft bolt D 6 Loosen locknuts A 7 Tighten or loosen the track adjusting screws B as necessary to provide equal adjustment on both sides of the track Slider Track Ten
59. g style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride A new rail slide will offer improved performance over a worn rail slide It can also improve top speed When riding on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are available from your dealer e Polaris offers track kits for improved flotation in deep snow See your dealer for assistance NOTE Keep the suspension pivot points lubricated This will reduce moisture and rust build up and ensure proper function of the suspension components Grease rear suspension pivots before adjusting the rear suspension Refer to Suspension Maintenance beginning on page 94 34 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 1 Turn the knob toward the S for a softer ride Turn the knob toward the for a stiffer ride 2a Soft Tension long end of cam to front 2b Medium tensio
60. heck for the presence of air in the fluid system See page 80 for more information or see your dealer for service amp WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always have the brakes serviced at the first sign of sponginess 46 PRE RIDE INSPECTIONS Before Starting the Engine 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 j Brake Lever Parking Brake Lever Lock 3 Master Cylinder Reservoir Cover N 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 NOTE Ifthe brake handle is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break The brake light on the console will light up when the parking brake lever lock is set and the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly and release it The lock will return to the unlocked position amp W
61. hicle 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 The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent 1 Remove brake master cylinder reservoir cover and gasket 2 Fill the master cylinder reservoir to between the MIN and MAX marks Reinstall the gasket and cover 3 Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles 4 WARNING Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock resulting in serious injury or death Always add brake fluid to the fill line as recommended 7 After bleeding is complete refill the reservoir to the proper level See page 79 8 Reinstall the gasket and cover 80 MAINTENANCE Headlights Headlight Adjustment 25 7 6 m 2 b 1 cm The headlight may be adjusted for vertical aim using the following procedure 1 Place the snowm
62. hill amp 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 Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system This condition may lead to a sudden loss of brakes and or fire and may result in serious injury or death 14 SAFETY Operator Safety Driving in Hilly Terrain amp 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 If you must cross the face of a slope keep your weight on the uphill side of the machine to maintain proper balance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill side of the machine pull the rear of the snowmobile around and point the front end and ski
63. ideration if the failure was due to wear or not the direct result of a defect Skis Ski wear rods Tracks Slide rails Suspension components Finished and unfinished surfaces Brake components Carburetor Throttle body components Seat components Engine components Clutches and components Drive belts Steering components Hydraulic components Batteries Circuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper en gine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjust ment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified compo
64. im MAINTENANCE Clutch System 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 amp 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 Any unauthorized modifications to clutches such as adding or removing weights will void the warranty CAUTION The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum performance See your dealer for service and adjustments A special tool is required to check for proper alignment Clutch Center Distance See your Owner s Manual Supplement for recommended center distance for your machine If adjustment is necessary see your dealer 83 MAINTENANCE Clutch System 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
65. in jet always use the lowest elevation and temperature that is likely to be encountered 56 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 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 SYSTEM WHAT IT DOES THROTTLE CONDITION 1 1 4 WARNING Excessive or repetitive use of brakes for high speed stops will cause an overheated brake system This overheated condition could cause sudden loss of brakes and or fire resulting in serious injury or death When traveling on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat and result in brake failure 57 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 amp 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 Only a stiff metal pole connecting the towed object and th
66. laris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our complete line of apparel parts and accessories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out 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 Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2008 600 IO Racer 600RR Owner s Manual P N 9921089 2 TABLE OF CONTENTS Introduction EE ur de 4 This section contains helpful information for owners and drivers and illu
67. 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 Skags must be replaced when worn to half their original diameter NOTE Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement 1 Raise and support the front of the machine so the skis are approximately 6 15 2 cm from the ground 2 Remove the attaching hardware and pry the skag A downward 3 Remove the forward portion of the skag Reverse this procedure for new skag installation 93 MAINTENANCE Suspension Maintenance Rail Slide Wear Measure slide thickness at several points along the Tu 7 16 rail Have your dealer 1 1 cm replace the slide when it s worn down to the top of the wear limit indicator P groove A Do not operate the snowmobile if slide thickness measures less than 7 16 1 1 cm 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 Check rear idler wheel bolts for tightness Check rear idler adjusting bolt locknuts for tightness Se
68. n short end of cam up 2c Firm tension long end of cam up 35 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 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 FRSS links that movement to the rear torque arm causing it to compress and raise the rear suspension up as one allowing the suspension to hit the bump only once and eliminating kickback Your FRSS is preset at the factory 36 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 res
69. ne damage which is excluded from Polaris war ranty coverage DRAGON mode usually heats up the exhaust system within 5 to 20 seconds depending upon the initial temperature of the exhaust sys tem Two different sounds may be heard when using DRAGON mode One sound is an erratic misfire that may be heard when the exhaust system is heating up The other sound is a consistent misfire with a slight rise in engine RPM when the exhaust system is at target oper ating temperature DRAGON mode maintains the engine speed between 4500 and 5100 RPM Be sure that the clutch engages at 5300 RPM or above to prevent forward creep of the vehicle See your dealer if the clutch needs ad justment Please refer to the Polaris jetting chart and use the recommended jet for current temperatures as this system is sensitive to jet changes 26 FEATURES AND CONTROLS Polaris DRAGON Ignition System 600 IQ Racer DRAGON Mode Operation 1 2 NOTE The vehicle will launch Warm up the engine and track See page 54 When staged at the starting line depress and hold the DRAGON button on the left handlebar 1 Slowly advance the throttle to the wide open position while keeping the button depressed Release the button when the start flag drops forward at wide open throttle 27 FEATURES AND CONTROLS Electronic Reverse PERC 600RR Electronic reverse will activate only if the engine RPM is below 4000 If your machine is r
70. nents use of aftermar ket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been dam aged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 108 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 Coverage on Snow Check units is automatic Although you do not receive a warranty card your dealership should have printed a copy of the warranty registration form This form is your proof of warranty Consumer Exclusions Each repair visit after the first twelve months of standard warranty coverage is subject to a 50 deductible The free Second Year Engine Service Contract applies to the first 5 000 miles or two 2 calendar years from date of purchase whichever comes first Tampering with the odometer shall void all warranties service contracts No extensions to cover
71. 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 If you look back for only two seconds your machine will travel about 120 feet If your speed is 60 MPH your machine will travel about 180 feet in two seconds Traveling at night requires extra caution Check headlight and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your machine to a stop in the distance illuminated by the headlight Driving on Slippery Surfaces amp WARNING Never attempt an abrupt change of direction when operating on slippery surfaces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces steering and braking control which may result in loss of control and serious injury or death Slow down and use extra caution when operating on slippery surfaces 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 down
72. nsion 76 D Driver Awareness 11 Driving Downhill 14 Driving in Hilly Terrain 15 Driving on Slippery Surfaces 14 Driving Responsibly 18 E Electrical Connections 97 Emergency Stopping 57 Engine and Carburetor Protection 96 Engine Break In 50 52 Engine Safety 10 Engine Service Contract 109 Engine Stop Switch 49 57 Engine Troubleshooting 100 102 Engine Warm Up 54 Excessive Speed 14 Exhaust 72 F Fall 87 Flushing the Cooling System 74 Front Rear Scissor Stop 36 Front Springs 33 Fuel Filter 70 Fuel Lines Rem 70 Fuel Premix 51 Fuel Pump 70 Fuel Recommendations 51 52 Fuel System Deicers 51 H Halogen Bulbs 82 Handlebar Adjustments 39 Handlebar with Riser Block 39 Headlight Adjustment 81 81 82 High Temperature Indicator 73 Hydraulic Brake Inspection 77 Ice and Snow Build up 13 IES d aks etie i URS 30 IFS Adjustment Options 30 IFS Components 30 Inadequate Snow Conditions 17 Independent Front Suspension
73. obile 98 V Variable Exhaust System 70 Vehicle Identification Numbers 6 W Warning Labels 20 23 Wear Strips 0 0 0 000000 43 Weight Transfer During Acceleration 38 Windchill Temperature Charts 19
74. obile 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 The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in step 2 NOTE Rider weight must be included on the seat 5 Turn the adjustment nut 1 located inside the hood just below the headlamp opening Turn the knob in or out as needed for proper aim 81 MAINTENANCE Headlights NOTE Do nottouch 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 from the spring retainer 2 a Lift spring carefully around E XQ wire harness 2 and flip to 83 outside of housing With the wire harness attached 1 to the bulb 3 withdraw bulb from housing Grasp bulb by metal base and carefully separate bulb from harness Installing the Bulb 1 2 3 82 Hold bulb by metal base and install into wire harness Insert bulb into housing Carefully flip spring back into housing placing it around wire harness Squeeze spring together until it is over the spring retainer and release Verify headlight a
75. occurs due to poor snow conditions additional wheel kits are available See your dealer for more information NOTE Track damage or failure caused by operation on ice or under other poor lubrication conditions will void the track warranty 90 MAINTENANCE Steering System Steering Inspection and Adjustment Each week or before a long ride check all fasteners and tighten if necessary Specifically check fasteners marked with a 91 MAINTENANCE Steering System Ski Alignment amp 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 The measurement between the skis at point X should be 1 8 to 1 4 greater than the measurement at point Y NOTE Ifthe skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may also be affected 92 MAINTENANCE Steering System Ski Skags amp 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
76. oken weights stuck lubricated SEE YOUR DEALER Foreign object caught or the rail slide melted to track clips due to lack of lubrica tion Machine may be frozen to ground Track may be iced up Chain is loose or broken chain tightener is loose SEE YOUR DEALER TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch SEE YOUR DEALER system components Bearing failure SEE YOUR DEALER chaincase jackshaft or front drive shaft Drive belt surface flat spots Inspect and replace if necessary Drive chain loose or worn sprocket teeth Inspect and adjust or replace broken Poor low RPM Worn drive belt Inspect and replace if necessary performance Excessive belt sheave SEE YOUR DEALER clearance Loose torque stop Inspect and adjust Sticky clutch SEE YOUR DEALER Engine doesn t Seized engine SEE YOUR DEALER Seizure is a result turn of poor lubrication inadequate fuel supply broken parts or improper cooling Hydrostatic lock Fuel may have entered crankcase while vehicle was standing or being transported SEE YOUR DEALER to correct cause Drain plug s are located on lower crank case for emergency draining Engine requires Poor gasoline or not Replace with fresh winter fuel more than enough fuel getting to normal pulls to engine start 101 TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to
77. on 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 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 NOTE Turn the set screw in clockwise to increase the distance between the sheaves and out counterclockwise to decrease the distance 3 Tighten the jam nut Clutch Center Distance See your Owner s Manual Supplement for recommended center distance for your machine If adjustment is necessary see your dealer Due to tolerances in belt length it may be necessary for your dealer to make minor adjustments in the driven clutch to achieve correct belt tension 85 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 86 MAINTENANCE Chain Tension 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 operatin
78. ose for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury The warranty on your entire machine is terminated if any equipment has been added or any modifications have been made to increase the speed or power of the snowmobile SAFETY Operator 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 amp 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 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 051039 approval The approval number and serial 0006 031 number will also be displayed on the label 4 Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helme
79. ottom of each carburetor about every 1000 miles 1600 km Inspect for contamination amp WARNING When draining the traps fuel spillage will occur Always work in a well ventilated area away from anything that may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the fuel warnings on page 55 1 Turn the fuel valve off Place a container or shop towels below the plug to catch drained fuel 3 Slide the clamp away from the drain plug and remove the drain plug from the sediment tube 4 Wipe residue from the plug and reinstall it Reposition and tighten the clamp 5 Repeat the draining procedure for any remaining traps 71 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 amp 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 The cooling system on liquid cooled models consists of the following major components Coolant bottle Water pump e Cylinders Heads nlet and outlet manifolds Pressure cap e Heat exchangers 72 MAINTENANCE Engine Cooling
80. ove 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 76 MAINTENANCE Hydraulic Brake Inspection Frequently inspect the brake lever reserve 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 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 amp WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 1 6 mm 77 MAINTENANCE Brakes Brake Components PN TX IE LIT LX LIT LET LIII LI 1 Brake Caliper 2 Chaincase 3 Brake Disc 4 Backing Plate 5
81. p on the pre filter in the air intake system Either condition may be caused by improper carburetor adjustment amp WARNING Improper carburetor adjustments may result in operator safety hazards as well as serious engine damage Always have your Polaris dealer perform any carburetor adjustments Jetting Guidelines Changes in altitude and temperature affect air density which is the amount of oxygen available for combustion In low elevations and cold temperatures the air has more oxygen In higher elevations and higher temperatures the air is less dense Carburetors on most Polaris models are calibrated for an altitude of 0 2000 ft 0 600 meters and ambient temperatures between 10 to 10 F 23 to 12 C All carburetors must be re calibrated if operated outside this production temperature and or altitude range The main jet installed in production is not correct for all altitudes and or temperatures CAUTION A main jet that s too small will cause a lean operating condition and may cause serious engine damage Jet the carburetors carefully for elevation and temperature according to the jetting charts in your Owner s Manual Supplement NOTE _ It s the owners responsibility to ensure that the correct jets are installed in the machine for a geographical area Be very careful when jetting down in warm weather As the weather turns colder it will be necessary to re jet upward to prevent engine damage When selecting the proper ma
82. r a machine before attempting ambitious maneuvers A snowmobile depends on the rider s body position for proper bal ance in executing turns traversing hills etc Always start on a smooth level area to begin building your operating experience Before allowing someone else to use your snowmobile know the extent of their operating skills Check to see if they ve taken a snowmobile safety course and have an operator s certificate For their protection as well as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions Your snowmobile is not intended for this kind of use Be courteous to oncoming traffic by dimming your headlights and reducing your speed When traveling in a group of snowmobiles don t tailgate follow too closely Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris Allow even more distance when driving on slippery sur faces or when driving in darkness or other low visibility conditions Be aware of any snowmobile traffic around your vehicle Drive de fensively to avoid accidents 18 SAFETY Ope
83. r 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 Track studding will enhance braking control on hard packed snow or ice but extreme caution is still required on such surfaces Steering ability may be reduced on hard packed snow or ice A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain The addition of carbide skags is recommended with studded tracks to help maintain proper vehicle steering and control Similarly if your machine is equipped with carbide skags or you re adding them it may be necessary to add track studs to maintain proper vehicle control Proper balance must be maintained between the number of studs and the length of carbide on skags The more studs used the longer the carbide on the skags should be See your dealer s track studding chart for recommended studding and skags Inspect skags and studs frequently Worn studs or skags may reduce steering and braking control on hard packed snow and ice Replace worn studs and skags to maintain proper balance and vehicle control When studded tracks are used in
84. r vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance see page 105 110 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 emission control system is designed built and equipped so it conforms to current U S Environ mental Protection Agency regulations applicable to snowmobile emissions under 40 1051 1065 and 1068 at the time of sale to the ultimate purchaser Polaris warrants that the engine is free from defects in materials and workmanship that may keep it from meeting these regulations The warranty period for this emissions certified snowmobile engine starts on the date when the engine is first purchased and continues for 4000 kilometers 2485 miles of vehicle travel 200 hours of operation or 30 calendar months whichever comes first This engine emissions limited warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty This includes compo nents whose failure increases the snowmo
85. rack Alignment 1 EmakTemon f e rowumrsp 1 RalSideCondo 9 f NA 1 1 3 XL e Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate eat C O pow REC 63 MAINTENANCE Lubrication Lack of lubrication will adversely affect your ride and the life of components Lubricate with Polaris Premium 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 For more information about suspension lubrication and adjustments see your Polaris dealer NOTE Lubrication points are indicated by a x in the following illustrations Rear Suspension 64 MAINTENANCE Lubrication Front Suspension Two components of the IO front suspension and steering require lubrication Grease the left and right spindles Raise the front end of the ma chine to permit better grease entry into the spindle area 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 a
86. rator Safety Windchill Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding WIND CHILL CHART Actual Thermometer Reading F Equivalent Temperature 2 5 _ 3 72 29 NEM ER 23 NENNEN 50 26 19 12 4 3 10 e 55 20 4 3 10 25 AMNEM pO ee ee EN Pp Prstbtein Somn WIND CHILL CHART Actual Thermometer Reading Equivalent Temperature Sree rrr errr rr rr rrr CES Ee GRUBER ES ES 5 0 RE EET ERE RARE 7 rds 9 v2 ESE m pm Fw pspepepwpm p p prp Fein atin m 19 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 The part number is printed on the decal Clutch Cover Warning This warning decal is found under the hood on the clutch cover
87. ris dealer See Frequency Page 150mi 500mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season Clutch y without belt Dive Bett Condition e 1 o e Ben T L foun sheaves ss EngineMounts Tifi f or J vg ENU M Engine Mounting Piate v v fi j Engine Torque Stop 8 vr j v jJ vr Cylinder Head Botts v j vr j r j CylinderBaseNuts r vr j v j vr j ignition TimingBroc v v jJ vr j gn coe me p xe joo CoolantLevel 79 e or m Water Pump Drive Bet NA v v j ipee Heat Exchangers 74 vr v j v j vr jJ v Coolant Circulation vr ovr vr j y CoolantLeaks rg or f vr j vg Spark Plug Condition ee 1 v j v j vr jr Exhaust Pipe S rr v y Exhaust Retaining 72 Springs Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 61 MAINTENANCE Periodic Maintenance Interval Table See Frequency Page isomi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season Brakes oseRoutng J T o HoseGondtion oo L2 Fues Baers 7 UT Baene o 1 1 2 LL emgBaes
88. s downhill Remount the machine restart the engine release the parking brake and descend the hill carefully 15 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 clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynamically balanced before installation Any tampering may disrupt this precision balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time especially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the machine into motion but always operate within safety limits Maneuverability While much control and maneuverability is achieved through the steering system and skis maximum control is achieved by the shifting of your body weight Maneuverability will change for lighter operators or machines designed to carry a load 16 SAFETY
89. s shown Choke and Cable Lubricate the choke slide 2 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 d possibility of the choke becoming frozen Siod 65 MAINTENANCE Lubrication 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 Clean the magnetic plug B whenever checking or changing lubricant CAUTION Mixing brands or using non recommended lubricants could result in excessive wear to internal components Always use Polaris recommended products for your vehicle 66 MAINTENANCE Spark Plugs 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 intern
90. sion Data C Track Measurement Measurement Location 600 Racer 10 Ibs 4 54 kg 16 ahead of rear 11 4 11 2 idler shaft 3 2 3 8 cm 600RR 10 lbs 4 54 kg 16 ahead of rear 11 4 11 2 idler shaft 3 2 3 8 cm 88 MAINTENANCE Track 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 Ibs 47 5 Nm 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 Inspect track alignment by looking through the track window to make sure the rails A are evenly spaced on each side If the track runs to the left loosen left locknut and tighten the left adjusting bolt If the track runs to the right loosen right locknut and tighten the right adjusting bolt 4 A
91. start Engine lacks power Engine continually backfires 102 Probable Cause Faulty ignition No fuel to engine Flooded engine nor mal situation caused by too much chok ing Poor engine compres sion Fouled or defective spark plug Fuel filter loss of high RPM power Incorrect clutching Carburetor and fuel pump Faulty plug s Carburetor 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 Check tank level and fill up with correct fuel Ice in fuel line filter or pump On the standard Polaris carburetor the choke will not function with the throttle depressed See second item under Probable Cause of Engine continually backfires Hold throttle open crank engine several times may be necessary to change plug s however the plug s may operate satisfac torily when dried Running too lean a mixture too small a main jet will cause seizure resulting in loss of power SEE YOUR DEALER This indicates a major engine problem that must be repaired before engine is run Change and test operation Check fuel filter flow Disconnect hose and drain about 1 2 cup Fuel flow should be steady and encompass the entire diame ter of fuel line If not replace filter SEE YOUR DEALER There s no adjustment to change power output SEE YOUR DEALER
92. strates the location of important identification numbers that should be recorded in the owner s manual Safety iie 7 This section describes safe vehicle operation and identifies warning decals and their locations Features and Controls 24 This section illustrates the locations of your snowmobile s controls and features The Perfect Fit 30 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 44 This section explains procedures that must be performed before riding 50 This section explains proper engine break in operation of features and operating procedures Maintenance 59 This section defines your role and your dealer s role in your snowmobile s regular maintenance Polaris Products 99 Troubleshooting 100 This section is a quick reference guide to solving problems Warranty lt o esdeu io niesiu enm Ra i 105 Maintenance Record 112 Index sets tsa ere eee ees eee DV 115 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
93. t face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 787 1 or CE Make sure protective eye wear is kept clean SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation amp WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated tc 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 We recommend having your dealer perform all track service and alignment procedures Stay Clear of Engine Never attempt adjustments with the engine running Stop the engine raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation 4 WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments Riding Position Operating a snowmobile requires skill and balance for proper control Rider positions may vary with experience but under most conditions the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle brake and steering control amp WAR
94. tions to help you achieve an optimum ride 38 THE PERFECT FIT Handlebar Adjustments Handlebar with Riser Block 1 Remove the handlebar cover to expose the handlebar mounting hardware 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 Adjust the handlebar to the desired angle Be sure the handlebar brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when the handlebar is turned fully to the left or right Torque the handlebar adjuster block bolts to 11 13 ft Ibs 15 17 6 Nm Replace the handlebar cover 39 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 Personal injury to self or others This applies to but is not limited to brakes clutches fuel systems and exhaust systems NOTE Exhaust systems are critical safety areas that must use approved Polaris parts Please see your Polaris dealer for service 40 THE PERFECT FIT Accessories Traction Products Another way to tailor you
95. to suit rider preference The machine should be methodically tested one change at a time under the same conditions trail and snow conditions vehicle speed riding position etc after each adjustment until the best ride is achieved IFS Components 1 Skis 2 Spindles 3 Front shocks and springs 4 Control arms IFS Adjustment Options e Front shock spring preload Compression damping see page 32 Optional springs Optional shock valving if equipped with Walker Evans shocks Toe ski alignment see page 92 30 THE PERFECT FIT IQ Front Suspension Adjustments amp 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 To determine if your machine is using full travel of the ski shock push the o ring travel indicator down as far as it will go on the shock rod and test ride the machine The o ring will move up on the rod in direct relation to the amount of travel If the shock travel is full the bumper will be seated at the top of the shock Shock Absorber Components 1 Retainer 2 Shock Rod 3 O Ring Travel Indicator 4 Body 5 Threaded
96. transport d un passager mod les approuv s seulement ralentir et pr voir une plus grande distance pour diriger et arr ter la machine Le transport d un passager r duit la manceuvrabilit du v hicule Lors de la conduite sur la neige durcie la glace ou de la travers e de routes les capacit s de braquage et de freinage sont consid rablement r duites Ralentir et pr voir une plus grande distance pour virer ou arr ter e Pour conserver le contr le du v hicule sur la glace ou la neige durcie utiliser une combinaison ad quate de patins de skis en carbure et crampons de chenilles Consulter le manuel d utilisation pour l usage correct des dispositifs d adh rence Des arr ts r p t s lors de la conduite haute vitesse peuvent causer la d t rioration ou la d faillance du syst me de freinage Le frein de stationnement peut se d tendre lorsqu il est serr pendant une p riode prolong e Ne pas laisser le freine stationnement serr pendant plus de 5 minutes Avant de d marrer le moteur v rifier le bon fonctionnement de la commande des gaz des freins et de la direction S assurer que le capot est verrouill Demeurez assis et en position pour contr ler le v hicule Syst me d injection d huile utiliser exclusivement du carburant non m lang V rifier le niveau d huile lors de l approvision nement en carburant 7173374 23 FEATURES AND CONTROLS Brake Lever Oil Light 600
97. ts are Coolant bottle or overflow tank Engine filler neck Pressure cap on some models Connecting hoses 73 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 4 WARNING Steam and hot liquids will cause serious burns to your skin Never bleed the cooling system or remove the pressure cap when the engine is warm or hot If the pressure cap needs replacement contact your dealer for the correct part Use of a non standard pressure cap will not allow the recovery system to function properly Bleeding the Cooling System CAUTION 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 using the following procedure 1 Allow the system to cool completely then loosen the bleed screw and fill the reservoir to the FULL COLD mark Tighten the screw 2 Apply the parking brake and run the engine at idle RPM until the thermostat opens 5 to 8 minutes
98. uble 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 Vary the throttle openings and machine speeds to reduce friction on all close fitting machined parts allowing them to break in slowly without damage Use of any lubricants other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris lubricants for your vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the machine Oil Recommendations Never mix brands of oil Serious chemical reactions can cause system blockage resulting in serious engine damage They may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates Polaris oils are compatible with each other See page 99 for the part numbers of Polaris products Recommended Oils 600 IQ Racer 2 Cycle Racing Oil 600RR VES II 2 Cycle Oil or 2 Cycle Racing Oil 600 IQ Racer The only source of engine lubrication for this engine comes from lubrication added to the fuel Always premix the fuel 600RR Engine lubrication com
99. ulting in improved cornering performance An adjustment dot is located on the RRSS This dot is on the longest end of the scissor stop Rear Rear Scissor Stop Attributes Moving the RRSS to a higher position or forward hole will have the following effects on the suspension Reduced weight transfer Improved chatter bump ride Improved cornering performance 37 THE PERFECT FIT IQ Rear Suspension Adjustments Weight Transfer During Acceleration IQ Rear Rear Scissor Stop RRSS The preferred method for controlling weight transfer during acceleration of the IO rear suspension is by adjusting the RRSS Use the ROTATE 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 To increase weight transfer or ski lift during acceleration move the RRSS to the rearward upper position The RRSS may also be rotated to a lower position for even more weight transfer if desired A Low Position This setting will increase weight transfer B Medium Position This setting is the production setting and will provide the best overall trail riding C High Position This setting will decrease weight transfer D Rearward Upper Position optional hole location This setting will increase weight transfer NOTE Your dealer can help you with initial set up and additional set up instruc
100. unning 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 amp WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle Look behind the vehicle before and while backing Avoid sharp turns Apply throttle slowly Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your vehicle is clear 3 Push the reverse button 1 on the left hand control for one second then release The engine will automatically reduce RPM and start a reverse rotation A flashing reverse light on the tachometer will indicate that the transmission is in reverse 4 Apply the throttle slowly to make sure the transmission is in reverse NOTE The maximum engine RPM will be 6000 when in reverse NOTE _ Ifthe engine stops running the snowmobile will be in forward gear when it s restarted 28 FEATURES AND CONTROLS Electronic Reverse PERC 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
101. ve 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 Before changing spark plug heat ranges be sure the correct main jet is installed in the carburetor s Refer to the Owner s Manual Supplement or see your dealer 1 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 NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation 4 Torque to 18 22 ft Ibs 24 30 Nm 5 Install spark plug cap 68 Intake Filter The intake foam filters limit snow ingestion into the intake system When operating in loose powder snow

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