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2008 600 RR / IQ RACER SNOWMOBILE SERVICE MANUAL

1. 11 2 IGNITION PACKS chin ye 11 2 EXHAUST VALVE SOLENOID 11 3 COOLANT TEMPERATURE SENSOR 11 3 KNOCK SENSOR 11 3 IGNITION CHASSIS REGULATORS 11 3 EXHAUST TEMPERATURE 11 3 IGNITION TIMING Jetmir saia aaa 11 4 TIMING PROCEDURE CARBURETED ENGINES 11 4 IGNITION TIMING 2 11 4 IQ RACER IGNITION TIMING CURVE 11 5 IQ RACER IGNITION TIMING CURVE SELECTOR 11 5 IQ RACER HOT LAMP ACTIVATION TEMPERATURE 11 5 600 RR HOT LAMP ACTIVATION TEMPERATURE 11 5 600 RR HOT CONDITION RPMLIMIT 11 5 DRAGON FIRE PIPE HEATER SYSTEM 11 6 SOLENOID CONTROLLED EXHAUST VALVES 11 6 THROTTLE POSITION SENSOR 5 11 6 TPS TEST TOOL 11 6 USING THE TPS TESTTOOL 11 7 TPS ADJUSTMENT CARBURETED MODELS
2. 4 10 DISASSEMBLY 4 10 ne dose Kab a 4 11 CARBURETOR ADJUSTMENT 4 12 THROTTLE VALVE SYNCHRONIZATION 4 12 FUELTANK 4 13 600 RR FUEL TANK ASSEMBLY 413 IQ 600 RACER FUEL TANK ASSEMBLY 4 13 EXHAUST SYSTEM 4 14 PIPE AND RESONATOR 5 4 14 WINNING PERFORMANCE 4 1 gt POLARIS Fuel Systems SERVICE WARNINGS AND PRECAUTIONS Service Warnings When servicing the fuel system it is important to heed the following warnings A WARNING PROPOSITION 65 WARNING onowmobile engines discharge fuel and exhaust which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm onto the snow on which they operate Keep this engine properly tuned and avoid unnecessary idling and spillage during fueling Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored or used Do not overfill the tank past the bottom of the filler neck If you get gasoline in your eyes or if you swallow gaso
3. 3 11 HANDLEBAR S te tle 3 11 SK li SKUSKAG FASTENER Ge 2 tori aeme qm eee e 16a Relief n 3 12 TRACK quce m 3 12 TRACK ALIGNMENT 3 13 ELECTRICAL SY OVENS i acon eee ee k aq t leid 3 14 HEADLIGHT BULB REPLACEMENT 3 14 OFF SEASON STORAGE puma aae eh 3 14 CHASSIS AND HOOD maa pupa ia a ces 3 14 CLUTOH AND DRIVE SYSTEM Sube saam 3 14 CONTPOLSANPBTINKAGE ope be 3 14 ELECTRICAL CONNECTIONS ctu costings on ners eg EEA 3 14 CARBURETOR THROTIEE BODY 35 3 335 aaa 3 14 a eee 3 14 CORROSION 3 14 3 14 DENTES 3 14 WINNING PERFORMANCE 3 1 gt POLARIS Maintenance PERIODIC MAINTENANCE Periodic Maintenance Schedule Periodic Maintenance Table 600 RR 600 IQ Racer Item 150 mi 500 mi 1000 mi 2000 mi BET BE Erza Erza gt lt 5 gt oS e un lt un e Cylinder Head Bolts Cylinder Base Nuts Spark Plug Condition I C
4. vendo 8 17 WINNING PE A FORMANCE 8 1 gt POLARIS Steering and Suspensions OVERVIEW SPECIFICATIONS Inspection When inspecting steering and suspension components for wear or damage always replace parts as necessary Refer to the assembly exploded views in this chapter for identification of components and torque values of fasteners Make notes of the direction a bolt goes through a part what type of nut is used in an application etc Some of the fasteners used in the IFS are special and cannot be purchased at a hardware store Always use genuine Polaris parts and hardware when replacing front end components Review steering adjustment guidelines before making adjustments The following components must be inspected at this time e Tie rods and tie rod ends Torsion bar and bushings linkage where applicable Handlebars and steering post assembly Spindles and bushings Skis and skags Idler arms e A arms and bushings Shock absorbers shock mounts springs All related fasteners check torque Refer to steering exploded views at the beginning of this section Grease all fittings Always follow rod end engagement guidelines Maximum setup width must be checked whenever front suspension components are adjusted or replaced Toe Specifications Toe alignment is measured at ride height This means that the machine is on the groun
5. 03 378 yq 81 Ta 800 401 1305 _ 3NI9N3 SISSVH2 31000 102 8 93 ________ 8 1131 034 3018 wa 81 1 100 4015 3NN SISSVF a 63 duds M HOLIMS 03 3018 wa 8 900 1102 405835 10 81 Q3H 3IIFM v3 v smvWNVHIHOIS 3116 89 9 900 _ 9145 MH Mol 1111 ___3078 0 81 00 102 3123 uouUboi d ________3217145 MO 3090 e Aw n d LHOLIMS uiiv3H v u3wsvMgnnHi C 81 ax 200 id H IINS 8 uevagnnu 9 x 100 _____ u0193NNO9 01 HOI 3NNO9 3909 ON 159 01 MIAVO WOI93NNOO 3dAL 199 SO S MOv SS3NuVH NOLLVNINHSI 000921 01083105 3 nogi 301911938 3339 1 020 QNO 4 31 331VN 0 3 INV1002 31000 102 gt 213 gt POLARIS iring W 2008 IQ 600 RR Chassis Harness 2 of 2 11 2
6. 11 11 INCORRECT TIMING 11 11 WINNING PERFORMANCE 11 1 gt POLARIS ELECTRICAL SYSTEMS ELECTRICAL SPECIFICATIONS Spark Plug Champion RN57YCC NGK BPR9ES 027 0 70mm IQ Racer Stator Specifications NOTE Use a multimeter to test the stator circuits Remember to test the circuits when the engine is cold and after the engine has been running for some time Resistance Values Output Specifications Vac Coil 10A 3000 RPM Yellow Brown 17A 6000 RPM Vdc Ignition Coil Blue Green 5 3A 3000 RPM IQ Racer Component Markings Flywheel 14 XF9201 4011869 Stator Magneto XS9201 4011870 DC Regulator 4011475 AC Regulator 4010793 Parts numbers are subject to change at anytime 11 2 600 RR Stator Specifications NOTE Use a multimeter to test the stator circuits Remember to test the circuits when the engine is cold and after the engine has been running for some time Resistance Values WHITE TO WHITE RED YELLOW TO BROWN RED TO BLACK RED 100 BROWN Output Specifications Vac Coil Yellow Brown 18 8A 4000 RPM 600 RR Component Markings Stator Magneto AC DC Rectifier Regulator 4011809 Component Flywheel Parts numbers are subject to change at anytime Ignition Coil Packs Resistance Values BLK or WHT TO SECONDARY LEAD E
7. AS 6 15 ROLLER REMOVA ut editt ded 6 16 TION s rod eit ari 6 16 CLUTCH ASSEMBLY see cod S acted Sect tate dere Sed epa dete ot e an ads 6 17 INDEXIBIG 2 Sx Rs tr 6 18 DRIVE CLUTCH INSTALLATION RP E REA 6 19 DAIVEN CLUICH mr 6 19 DRIVEN GEUTCH REMOV u u Tu 6 19 DRIVEN GLUTCH INSTALLATION x 2 et oe obs finde te 6 19 GOMPONEN oie wether sasa eee eee eee we 6 20 WINNING PERFORMANCE 6 1 gt POLARIS PVT System PVT SYSTEM Overview CAUTION Because of the critical nature and precision balance in corporated into the PVT system it is absolutely essen tial that no attempt at clutch disassembly and or repair be made without factory authorized special tools and service procedures Polaris recommends that only au thorized service technicians that have attended a Po laris sponsored service training seminar and understand the proper procedures perform adjust ments or repairs The Polaris drive system is a centrifugally actuated variable speed belt drive unit The drive clutch driven clutch and belt make up the torque converter system Each clutch comes from the factory with the proper internal components installed for its specific engine model
8. 17 SV CHIE a Dsi u bay SUS 11 8 BRAKE LIGHT 11 8 HEAD IIS SI SS suis hoe E e E 11 8 HANDWARMER THUMBWARMER SWITCH 11 8 DRAGON FIRE SWITCH 11 8 AUXILIARY ON OFF SWITCH 11 8 TETHER SWITCH 11 8 KEY SWITCH 600 RRONLY 11 8 OIL LEVEL SWITCH 600 RR ONLY 11 8 REVERSE SWITCH 600 ONLY 11 8 2008 600 RR REGULATOR 11 9 DETONATION CONTROL DET 11 9 2008 600 RR OVERVIEW 11 9 VARIABLE EXHAUST SYSTEM VES 11 9 OVERVIEW aaa aa 11 9 ELECTRONIG REVERSE 11 10 OPERATION T 11 10 FORWARD 11 10 AETITUDE SETTING S ossi Qd etate tite mds date kamas 11 10 IMPORTANT 8 11 10 TROUBLESHOOTING TABLES 5 2 3 4 9 eile abd 11 11 NO IGNITION SPARK
9. oS he b usun RC Som ci m 4 3 MIKUNIDE F NEEDLES prr a de dim o Roc M c e 4 4 MIKUNI SHORT 5 4 4 MIKUINIAEONG PILOT AIR JE TS rete So PESE PE EP PES 4 4 MIKUNI PISION VALVES 955552 HO A RU SERE 4 4 MIKUNI NOTCHED PISTON VALVES 4 4 MIKUNI CARBURETOR 4 5 FUNG HON 45 FEOAT SYSTEM LU 45 PUBL METERING e gels deest t da ec z uel 45 45 s beige hee ale eee ee 4 6 FUEL SGREW en ee ee ee ate 4 6 MAIN IEW se zc ans gt gt eae we 4 6 JETTING GUIDELINES uz sd DS Uus bb S ie 4 6 PISTON VALVE OR THROTTLE 4 6 JETNEEDLE rs Bie eee ota rau erc 4 7 cha JE abuti Coe eR 4 7 THROTTLE OPENING VS 48 acne neces 49 FUEL PUMP OVERVIEW 4 9 MAINTENANCE 2 Rex Ee REESE awh RSME ee 49 CARBURETOR
10. carburetor slide 1 loosen the Phillips head screw located under the top cover on the MAG carburetor While holding the PTO carburetor slide flush to the top of the carburetor rotate the synchronization nut clockwise to raise the slide and counterclockwise to lower the slide ee Sync Nut Adjust the synchronization nut until it is even with the PTO slide Once this is flush lock the locking screw Replace the carburetor covers If removed reinstall the fuel vent throttle and choke hose and cable connections Verify and set throttle cable free play WINNING PERFORMANCE gt POLARIS Fuel Systems FUEL TANK 600 RR Fuel Tank Assembly FUEL SHUTOFF VALVE FILTER GROMET FITTING IQ 600 Racer Fuel Tank Assembly FUEL SHUTOFF VALVE FILTER FOAM PADS FITTING WINNING PERFORMANCE 41 C POLARIS 3 Fuel Systems EXHAUST SYSTEM Pipe and Resonator Assembly A EGT Sensor 32 Ft Lbs 44 Nm B Exhaust Manifold Fasteners 22 Ft Lbs 30 Nm NOTE Always use the stainless steel gray springs to connect the exhaust pipe to the exhaust manifold 4 D o gt Engine and Cooling Systems CHAPTER 5 Engine and Cooling Systems ENGINE SPEGIFICATIONS z x iya ba Sas POPSET REOR i 52 FASTENER TORQUE GUIDE 13 52 accen s oem de ee oie mauwa wou bad eee aces 5 2 COMPONENT TORQUE SEQUENGES ehi er
11. Systems Jackshaft Removal 8 Install the chaincase cover and torque the cover fasteners to specification 1 Drain the chaincase oil into an appropriate container 2 Remove the drive belt T 3 Remove the driven clutch noting the number and location 7 of the driven clutch offset washers he chai Chaincase Cover Fasteners 4 Remove the chaincase cover 8 ft lb 11Nm 5 Relieve tension on the chain tensioner 6 Remove the cotter pin on the jackshaft 9 Replace drain plug and fill the chaincase to the safe level 7 Lock the parking brake and remove the nut on the top gear of the dip stick 8 Remove the lower gear fastener gt Driveshaft Removal Installation 9 Remove the upper gear lower gear and chain from the Remove the drain plug and drain the chaincase fluid chaincase 1 Turn the fuel petcock to the OFF position 10 Remove the jackshaft flange from the driven clutch side of 2 Remove the side panels the jackshaft 3 Remove the exhaust system 11 Hold the brake disc and slide jackshaft out through the Remove the intake plenum flange side 5 6 12 Inspect drive shaft and jackshaft in bearing contact area If diameter is 001 025 mm less than non contact area shaft replace the jackshaft Replace the chaincase drain plug and torque to specification 1 Insert the jackshaft through the brake disc and chaincase Drain Plug Torque bearing 10 ft lb 12 Nm 2
12. 000 wmm 389 Shocks Walker Evans Shock Valve Part Numbers 7 16 1 0 PARTNUMBER _ E 38930 090 WASHERS 4 WINNING PERFORMANCE gt POLARIS Shocks Valve Shim Arrangement NOTE The rebound and compression valve stacks will always be positioned as shown in the Shown below is an example of how valving stacks are illustration regardless of how the shock assembly is arranged installed on the snowmobile FULLY COMPRESSED SHOCK ROD FULLY EXTENDED PISTON SHOCK ROD JSS k IZA REBOUND VALVE STACK COMPRESSION VALVE STACK Piston Orientation NOTE On some Walker Evans shocks piston is color coded The face of the piston with the greater number of relief COMPRESSION SIDE ports will always face the rebound valve stack Red REBOUND SIDE Relief Port Faces Rebound Stack Faces Compression Stack INNING PERFORMANCE 9 5 Shocks SPECIFICATIONS 2008 600RR 600 IQ Racer Shock Specifications IFS Shock EXTENDED COLLAPSED STROKE IFP DEPTH SHOCK PN MODEL LENGTH LENGTH OIL VOLUME IN MM IN MM IN MM IN MM 7043345 600RR 800 IQ 18 343 11 384 7 00 7043360 465 9 289 2 177 8 FTS Shock EXTENDED COLLAPSED SHOCK PN LENGTH LENGTH IN MM IN MM 8 51 4 07 216 2 103 4 RTS Shock IFP DEPTH IN
13. IQ 121 Racer WINNING PERFORMANCE C POLARIS Maintenance Track Alignment NOTE Track alignment affects track tension Misalignment of the track will cause excessive wear to the track rail slides and rail NOTE Excessive rail slide wear occurs due to running in inadequate snow conditions Periodically check that the track 1 centered and running evenly on the slide rails Misalignment will cause excessive wear to the track and slide rails 1 Safely lift and support the rear of the snowmobile off the ground Rotate the track by hand to check for any possible damage 3 Inspect the track rods A carefully and examine the track along the entire length of each rod bending the track edge and inspecting it for breakage If any rod damage is found the track should be replaced 4 Warm up the track by starting the engine and apply a small amount of throttle so the track runs slowly at least five complete revolutions 5 Stop the engine and turn the ignition off Inspect track alignment by carefully looking through the track window B to make sure the rails C are evenly spaced on each side 7 If the track runs to left loosen left locknut and tighten the left adjusting bolt D If the track runs to the right loosen the right locknut and tighten the right adjusting bolt It may be necessary to check this with the engine rotating the track Be sure to SHUT THE MACHINE OFF before making any furt
14. 11 4 IQ 600 Racer Fuel Tank Assembly 4 13 IQ 600 RR Steering Assembly 8 7 IQ Racer Steering Assembly 8 6 J Jackshaft Installation 7 9 Jackshaft Removal 7 9 Jetting Guidelines 4 6 L Light Bulb Replacement 3 14 Lower Spherical Bearing Replacement 8 10 Lubrication Chaincase Oil 3 8 Choke Cable 3 8 IX 2 Front Suspension 3 8 Rear Suspension 3 8 Throttle Cable 3 8 M Maintenance Products 3 4 Master Cylinder Lever Service 7412 Mikuni Long Pilot Air Jets 4 4 Mikuni Short Pilot Air Jets 4 4 Mikuni Carburetor Components Float System 4 5 Fuel Delivery 4 5 Fuel Metering 4 5 Function 4 5 Jet Needle 4 7 Main Jet 4 6 Needle Jet 4 7 Pilot Air Screw 4 6 Pilot Jet 4 6 Piston Valve or Throttle Valve 4 6 Mikuni Jet Needles 4 4 Mikuni 4 3 Mikuni Notched Piston Valves 4 4 Mikuni Pilot JelS 4 3 Mikuni Piston or Throttle Valve Part Numbers 4 4 MIKE Starter Jets tesi iade 4 3 Mikuni 38 40 Flat Slide Service Disassembly 4 10 Mikuni TM38 Flat Slide Service Assembly 4 11 Model Number Designation 23 Model Spec
15. 375 1 1 2 12 1 27 64 25 54 See ee See 3906 10 mm 3937 1 3 4 5 19 16 4063 1 3 4 12 1 43 64 27 64 4219 mm 4331 2 4 1 2 1 25 32 qe 5 16 18 2 12 15964 15 sees ces oe 4688 12 mm 4724 5 16 24 2 1 4 4 1 2 2 1 32 eco eden 4844 3 8 16 2 1 2 4 214 13mm 5118 3 8 24 2 3 4 4 2 1 2 99 04 aoe 5156 7 16 14 3 4 2 3 4 Ad cles T ee feces ose see eet eee ete se mm 716 20 2964 Db cesta alui emi inae 5625 I 5781 15 mm 5906 Metric Tap Drill Sizes 6 2 5938 39 64 6094 Decimal Nearest 5 8 625 16 6299 Size Drill Equivalent 41 64 6406 X50 1009955 195982 1 e 21 32 6563 17 mm 6693 43 64 6719 3 60 13532 0 09897 35822 1 6875 4 70 oi qe 7031 18 mm 7087 4 75 18 10410511801 23 32 7188 80 47 64 eheu Bee ese eeu sap ss 7344 19 mm 7480 eee 3 4 6 5 90 7656 6 1 00 9 10196 1364 7813 20 mm 7874 7x1 00 7969 axi00 g 19392 vvv 1316 8125 21 mm 8268 8281 8 1 25 17 64 0265 17 644 8438 9x1
16. gt WINNING PERFORMANCE 3 3 Maintenance MAINTENANCE PRODUCTS Engine Oils Lubricants Misc DESCRIPTION PART NUMBER Premium 2 Cycle Oil 2 5 Gallon 16 Gallon 55 Gallon 330 Gallon VES Gold 2 Cycle Oil 2 5 Gallon 16 Gallon 55 Gallon 330 Gallon Racing 2 Cycle Oil Quart Gallon 16 Gallon PS 4 4 Cycle OW 50 Oil Quart 55 Gallon PS 4 4 Cycle 2W 50 Oil Quart Gallon 16 Gallon 55 Gallon Synthetic Chaincase Lubricant DESCRIPTION PART NUMBER Premium All Season Grease 307 Grease Gun Kit 1407 Carbon Clean Plus 2871326 Isopropyl 2870505 Fuel Stabilizer Quart 2 5 Gallon Cross Shaft Assembly Lubricant 807 2 5 Gallon Three Bond Sealant 507 2871557 Loctite 242 2871950 WINNING PERFORMANCE gt POLARIS DRIVE DRIVEN CLUTCHES Belt Deflection Inspection Too much belt deflection is when the belt is too long or the center distance is too short The initial starting ratio will be too high resulting in performance loss This is due to the belt rising too high in the drive clutch sheaves upon engagement A Not enough belt deflection B is when the belt is too short or the center distance is too long The initial starting ratio will be too low In addition the machine may creep when the engine idles causing damage to the internal face of the drive belt Belt too high on initial engagement 1 Measure the belt deflection with both clutches at rest and in thei
17. 5133887 5133904 62 46 46 ieee 66 46 46 64 38 65 66 40 55 58 34 46 515955 60 34 65 Do not install a non ER helix on a Perc equipped snowmobile where the engine changes directions 6 8 WIMNINSOG FER FOR M AME POLARIS System Team Springs TEAM Driven Springs mms 7043061 Red Silver 7043057 Red Blue 7043063 Black Red 7043069 Red Pink 140 7043363 Black Purple 160 EE GN 7043254 Black 140 300 140 NOTE Team driven springs listed with a color will have the beginning and ending spring rates painting on the spring coils Tag the spring with the part number when not in use C POLARIS 6 9 PVT System Drive Belts Belt Width Projected Side Angle Overall Center to Number aes in cm 3211080 11 5729 2 3211078 1157292 11 27 9 11 27 9 3211117 3211121 3211122 1 46 37 1 1 438 36 5 10 625 27 1 46 37 1 11 5 29 2 Belt dimensions are given in nominal dimensions There is a variance for all critical dimensions Clutch set up must be inspected when a new belt is installed and if necessary adjusted 11 5 29 2 3211114 3211115 The drive belt is an Important component of the converter system In order to achieve maximum efficiency from the converter drive belt tension deflection clutch offset and alignment must be adjusted properly Belt Inspection Proje
18. 7 13 WINNING PERFORMANCE 7 1 POLARIS Drive and Systems GEAR RATIO SPEED CHART Chaincase Speed Charts RPM Gd Sa Nd MG Gd aad MCN ILI Ld o E We LIE LO d Ld Cd d Ll aded Le el Ga d od d a e CN wu NENNT ENIM id e d d d dal o a BM od dd n d d lai d dd el al ME d d el d d c d al a al MN d d d d d a d d d o od c d BEN Gd d GG d GR 9 7 2 POLARIS Drive and Systems flint la ic ll el KA bl dd le cal e rd Jackshaft RPM E ES SETS dial Lis d a LLL K LL LL 4 A LLL LLL LL KE BL Lbs La cu had La Kl Lad ted Gad id le d 5 o d d nd nd gt POLAR
19. EXTENDED COLLAPSED LENGTH LENGTH IN MM IN MM DEPTH IN MM 9 65 5 35 245 1 135 9 9 6 WIMNINMAO PERFORMANCE POLARIS Shocks Shock Valve Shim Stack Configurations NOTE All measurements inches SHOCK PN 7043345 7043360 7043312 7043354 7043311 630 x 063 1 000 x 012 100 x 012 1 00 x 090 100 x 012 900 x 010 100 x 012 1 000 x 010 100 x 015 1 100 x 010 200 x 012 1 200 x 012 200 x 012 1 300 012 250 015 1 450 x 012 65 x 063 900 x 015 1 000 015 1 100 x 015 1 100 015 1 200 x 015 1 300 015 1 450 x 015 REBOUND Piston Orifice COMPRESSION ADJUSTER 200 015 250 015 00 x 010 00 x 010 00 x 010 00 x 010 1 300 x 015 1 250 x 015 800 x 012 1 100 x 015 1 000 x 015 900 x 015 800 x 015 00 x 015 1 100 x 012 900 x 012 800 x 012 1 200 x 125 1 10 x 025 1 00 x 025 625 x 065 1 000 x 012 1 500 x 010 1 550 x 010 1 500 x 010 1 000 x 012 1 550 x 012 1 500 x 012 1 450 x 012 1 300 x 010 1 200 x 010 1 100 x 010 900 x 010 1 250 x 090 1 10 x 025 1 00 x 025 1 00 x 025 00 x 010 625 x 065 900 x 015 900 x 012 900 x 010 900 x 010 1 450 x 015 1 450 x 015 1 450 x 010 900 x 010 1 450 x 010 1 450 x 010 1 100 x 010 1 000 x 015 900 x 015 900 x 015 1 500 x 100 1 10 x 025 1 00 x 02
20. 010 030 25 75mm Torque Stop Jam Nut 15 17 ft lb 21 24 Nm NOTE Where applicable when installing a new torque stop position bumper so the tip is just touching crankcase ENGINE MAINTENANCE Surge Tank Keep the level of the coolant inside the surge tank at the FULL COLD level mark when the coolant is at room temperature Always add coolant when the cooling system is COLD Never remove the fill tube pressure cap when the cooling system Is warm Severe burns to skin may occur from escaping coolant or steam 3 6 Recommended Coolant Use Polaris Premium 60 40 antifreeze This premium antifreeze is rated for temperatures down to 62 F 52 C Cooling System Bleeding 1 Allow the cooling system to cool completely Verify the coolant level in the surge tank is at the COLD mark 3 Remove the pressure cap and fill the fill cap with coolant to the base of the pressure cap seat Loosely install the pressure cap 4 Elevate the front of the machine slightly 5 Apply the parking brake and start the engine 6 Allow the engine idle time to stabilize then set the RPM to approximately 600 RPM 7 Immediately add coolant to the fill tube if the coolant level dropped significantly after the engine started Watch the level and add more coolant until the level stops dropping 8 Secure the pressure cap 9 Verify the tunnel coolers begin to warm up as the engine continues to run 10
21. 11 12 13 14 If throttle slide was removed install throttle slide 11 so that the wider face Is facing the engine side of the carburetor Install the funnel gasket 13 and funnel 12 onto the carburetor You will have to lift the throttle slide up and place the smaller face into the funnel area Install funnel screws 10 Install the e clip 8 in the desired position on the jet needle 7 Slide the plastic washer 9 on the jet needle so that it is positioned to rest on top of the throttle valve when assembled Install carburetors on engine Replace top cap gaskets 3 cover 2 and screws 1 Check throttle lever free play CARBURETOR ADJUSTMENT Throttle Valve Synchronization All throttle valve synchronization adjustments are made to the MAG throttle valve The PTO throttle valve is non adjustable and considered the base throttle valve Throttle valve synchronization can be performed with the carburetor rack installed or removed from the engine ES 4 12 If running turn off engine Remove the air box Remove the carburetor covers Hold the throttle bell crank wide open on the carburetor The bottoms of each throttle valve should be flush with the top of the intake bores If adjustment is required hold the PTO carburetor flush with the top of intake bore Turn the throttle stop screw in or out to set the PTO throttle slide flush with the intake bore 6 10 11 12 Once
22. 1 020 1 44KQ 1 50 2 10KQ 2 20KQ 3 09KQ 3 23KQ 7 89 8 23KQ Resistance PK to YEL 1 96KQ 2 04 0 No Change Racer Hot Lamp Activation Temperature The CDI will activate the gauge or dash mounted hot lamp whenever the engine coolant temperature is at least 221 F 105 C The hot lamp is the only warning to alert the operator of an over heating engine The CDI will not limit RPM initiate a mis fire or retard timing 600 RR Hot Lamp Activation Temperature The CDI will activate the gauge or dash mounted hot lamp as shown in the table 2008 600 RR Hot Lamp RPM TEMPERATURE F 75 5000 8000 THROTTLE POSITION me 30 221 105 199 93 208 98 CE POLARIS 600 RR Hot Condition RPM Limit The CDI will enter a RPM limit mode as shown in the table 2008 600 RR Hot Condition RPM TEMPERATURE F C 30 sm THROTTLE POSITION 11 5 ELECTRICAL SYSTEMS Dragon Fire Pipe Heater System The Dragon Fire system allows the operator racer to pre heat the exhaust pipe and hold the engine ata RPM Just below clutch engagement In order to generate the fastest hole shot with maximum engine horsepower The system 1 activated via a button on the left hand handlebar When pushed and held will enter the Dragon Fire mode The operator racer then apples the thr
23. 110 279 Height in cm 44 11 8 Estimated Dry Weight Ib ke Fuel Gallons Liters 4 15 14 Oil Quarts Liters Pre Mix 32 1 Cooling System Capacity 4 3 8 Quarts Liters Brake Fluid DOT 4 Front Vertical Travel Inches cm 11 5 29 1 Suspension Setup Width Not Adjustable Inches cm Drive Belt Part Number 3211114 Width inches 1 46 3 72 Side Angle 26 Camber Inches cm Not Adjustable Circumference inches cm 45 20 114 8 Toe Out Inches cm 0 1 8 0 0 31 Center Distance inches cm 10 625 27 Ride Out inches mm 10 2 5 Rear Suspension Walker Evans 16 Position Compression Adjustable Piggy Back Reservoir Race Valving Chaincase Center Distance inches 7 92 Top Gear Stock 19 Bottom Gear Stock 45 Chain Stock 76 Gear Lube Polaris Synthetic 80W Capacity oz ml 9 266 2 Rear Track Shock RTS Electrical Torsion Spring Diameter 359 Angle 77 Rear Travel Inches cm 13 9 35 3 Alternator Output Operating Voltage 13 5 14 5 Vdc Watts 13 5 Vdc Total 220 Ienition Timing Spark Plug Gap in mm Timing Box Setting Track Width Inches cm 14 75 37 5 Length Inches cm 121 307 3 Lug Height Inches cm 1 75 4 4 Track tension sag in cm with 10 Ibs 4 54kg placed 16 in 1 1 4 1 1 2 3 2 3 8cm 40cm ahead of rear idler shaft WINNING PERFOR
24. 5 1 9 gt POLARIS WIHNING 11 4
25. 7 Inspect the cylinder head combustion domes for any damage Measure cylinder head flatness Replace cylinder head if required 8 Loosen all then remove the cylinder bolts Clean the bolt threads to remove any thread locking residue 5 22 10 11 12 13 14 15 CYLINDER HEAD O RINGS CYLINDER BASE GASKETS Carefully pull each cylinder upwards taking care not to drop the piston and rod abruptly against the crankcase Remove the cylinder base gaskets Use a gasket scraper to clean the gasket residue from the crankcase and cylinder bases Inspect the cylinder walls Nicasil cylinders can only be lightly honed Damage that cannot be removed with a light hone requires cylinder replacement or re chroming The assembly process is the reverse of disassembly Always use new gaskets and o rings during assembly Liberally coat the inside of each cylinder and the outside of each piston with Polaris two stroke engine oil When installing a piston into a cylinder verify each piston ring opening is located at each piston ring locating pin Squeeze the top ring then carefully slide the cylinder over the compressed ring Do the same with the bottom ring Follow the torque specifications and torque sequences located at beginning of chapter when tightening fasteners WI HH lI PERFOR MAHCE C POLARIS Engine and Cooling Systems 600 RR Recoil Magneto RECOIL HUB FRICTION PLATE FRICTION SPRING 5
26. CAUTION A Main Jet that is too small will cause a lean operation condition and may cause serious engine damage Jet the carburetors carefully for elevation and temperature according to the jetting charts in the Specifications Chapter of this manual or the models Owner s Manual Supplements Piston Valve Or Throttle Valve fox E E llim _ __ THROTTLE VALVE JET NEEDLE CUTAWAY ANGLE AIR FLOW NEEDLE JET intake side k The throttle valve controls the rate of engine air intake by moving up and down inside the main bore At small throttle WINNING PERFORMANCE gt POLARIS Fuel Systems openings air flow control is performed chiefly by the cutaway The last number 57 indicates that the outside diameter is By controlling air flow the negative pressure over the needle 2 57mm The smaller the O D the richer the mixture valve is regulated in turn varying the fuel flow 90 01 57 The throttle valves are numbered 1 0 1 5 2 0 etc according to the size of the cutaway in millimeters The higher the number the leaner the gasoline air mixture Leaner Jet Needle The jet needle tapers off at one end and the clearance between the jet needle and the needle jet increases as the throttle valve Richer opening gets wider The air fuel mixture ratio is controlled by the height of the E ring inserted into one of the five slots provided in the head of t
27. Fast installation of the peran rod and assembly may displace the internal floating piston IFP from its original position Performance issues will be a result if the IFP is not in its specified position 16 Tighten the cylinder head onto the shock body 17 Verify the IFP is set at the specified depth If not verify there is oil on top of the IFP then open the bleed screw 18 Set the IFP to specification then close the bleed screw 19 Pour out any remaining shock oil from the reservoir 9 42 Chassis CHAPTER 10 Chassis 10 2 BULKHEAD AND TUNNEL 10 2 FOOTREST STRUCTURE 10 3 CONSOLE AND SEAT 10 4 CONSOLE ASSEMBLY VIEW 10 4 SEA yee Be abe rae a a 10 4 10 5 HOOD ASSEMBLY VIEW 10 5 HOOD MOUNTING AND BUMPER 10 6 NOSEPAN AND SIDE PANELS 10 7 ASSEMBLY VIEW 53 Ge er ce didus ede eds ict 10 7 PER FORMANCE 1 0 1 POLARIS Chassis CHASSIS Bulkhead and Tunnel HOSE PROTECTOR RACER ONLY AIRBOX BRACKET CDI BRACKET FUEL
28. NOTE Install belt so that the numbers can be read correctly on the left side of the machine or in the direction in which the belt was originally installed 2 Remove the wrench Wiggle the belt to remove slack while removing the wrench 3 Close the clutch guard 6 12 Adjusting Belt Deflection Team Driven Clutch NN JAM NUT DEFLECTION STUD 1 Loosen the jam nut Using an 1 8 Allen head wrench turn the stud counter clockwise to decrease belt deflection and clockwise to increase belt deflection 3 When the proper belt deflection is achieved torque the lock nut to 90 110 in Ib 10 12 Nm NOTE When using a MBL drive belt the belt deflection should be set so that 9 to 10 of the outer cogs are outside of the driven sheaves gt POLARIS PVT System PVT SYSTEM ADJUSTMENTS Clutch Alignment Offset The engine is mounted in the bulkhead so the drive and driven clutches self align under high torque loads Offset is controlled by the number of washers installed on the jackshaft behind the driven clutch 1 Remove drive belt 2 Install the correct alignment tool depending on the type of driven clutch installed on the snowmobile TOOL PART NUMBER APPLICATION PS 46998 Standard Team Driven PS 47477 Light Weight LW Team Driven NOTE A standard alignment tool will not work with a Team LW driven clutch Likewise a LW alig
29. Therefore modifications or variations of components at random are never recommended Proper clutch setup and adjustments of existing components must be the primary objective in clutch operation diagnosis Drive Spring The drive spring opposes the shift force generated by the clutch weights and determines the neutral RPM engagement RPM and wether the engine RPM remains flat rises or falls during shift out When changing only the drive spring installing a spring with a lower pre load rate will result in a lower engagement RPM speed while installing a spring with a higher pre load rate will result in a higher engagement RPM Clutch Weight The clutch weights generate centrifugal force as the drive clutch rotates The force generated changes in relation to the engine RPM and with specified weight of each clutch weight When changing only the clutch weights a lighter weight will result in a higher engagement RPM lower shifting force and higher shift out RPM Installing heavier weights has the opposite effect Neutral Speed Engine RPM when the force generated by the clutch weights 15 less than the pre load force generated by the drive spring In this mode the drive clutch is disengaged Engagement RPM Engine RPM when the force generated by the clutch weights overcomes the drive spring pre load force and the moveable sheave begins to close or pinch the drive belt The 6 2 engagement mode continues until no more belt s
30. Turn off the engine once the tunnel coolers are sufficiently warmed up Release the parking brake 11 Allow time for the coolant temperature to cool Re check the coolant level in the surge tank Add more coolant if required 12 Reset the engine idle RPM to specification Exhaust Valve Cleaning The exhaust valve guillotines must be cleaned to ensure maximum engine performance and throttle response gt A FASTENERS EV ASSEMBLY A GASKET 1 Remove the vent hose from the fitting Remove the two fasteners that secure valve assembly to the cylinder but not the two screws that secure the cover to the EV base 3 Carefully extract the guillotine out of the cylinder Discard the gasket 4 Using aclean rag or shop towel remove the oil residue from WINNING PERFORMANCE C POLARIS Maintenance the cylinder guillotine and EV base 5 Inspect the guillotine for signs of damage Replace guillotine if damage is found and inspect the cylinder and piston for damage 6 Clean the guillotine with brake cleaner and a piece of fine steel wool Clean only to remove hardened carbon deposits 7 Once clean rinse blade with mild detergent and water Dry completely 8 Install a new gasket then reinstall the EV assembly Apply Loctite 242 to the fastener threads then torque to specification 9 Reconnect the vent hose NOTE obtain maximum exhaust valve performance Polaris rec
31. 00 55 64 8594 22 mm 8661 7 8 1895 9x1 25 SA 8906 23 mm 9055 10x1 25 1132 103447 117 32 20 319 pause 9063 10x1 50 59 64 9219 1 1x1 50 61 64 xia 15 16 e d yid ed 24 mm 9449 12 1 50 13 32 10406 01332 O p P TE us kala 9688 25 mm 9843 12x1 75 63 64 9844 NEN je dct dot Decimal Equivalents WINHHNHIHNG POLARIS P E H FORMANCE 2 9 General Information Measurement Conversion Chart UNIT OF MEASURE CONVERTS TO ft lb x 12 in Ib in Ib x 0833 ft Ib ft Ib x 1 356 in Ib x 0115 kg m 7376 ft lb x 7 233 ft lb x 25 4 mile x 1 6 in i Ounces 02 grams g grams g Ounces oz Cubic Inches x 16 387 Centermeters Cubic Centimeters Cubic Inches Imperial pints liters 1 liters 1 Imperial pints Imperial quarts liters 1 liters 1 Imperial quarts Imperial quarts US quarts US quarts Imperial quarts US quarts liters pa x 6 895 Kilo pascals kPa square inch psi Pounds force Kilo pascals kPa x 145 sere i h 2 B f 3 m gt mm in I dz 2 10 Piston Wash Spark Plug Reading Changing temperature barometer altitude and fuel supply are just a few of the factors that can affect the day to day
32. 1 1 1 I I I I I I I N3349 avd 90 N33u9 19 x N 3018 __ _60 Fania 16917 0 __ 98 NVI 39138 98 5 81031 0105 JMLI9TE NV49VI NI 114114415 01 53 11 Q3HSVO 80 01105 48 03183518418 3UV S3UIM ANNONO 8311 8 GNNOUD Au3iivg W081 1009201 uiiuvis 81 90 1004201 __ 4991 QION3TOS LAVIS 3081 1003201 uiluViS 8I JLIHM N3349 uiluviS W9GI 01083105 Luvs 0817 5 2112313 81 O3u 31IHM ____ 3062 1102812 Levis 21812313 81 u3MOd OV 3081 1003201 15 WOSI IuviS 21412313 91 ____ SISSVHO __ 1003201 15 3081 18 1 21412313 81 10 ______ ____ __ YOLOSNNOD ALIAV9 HOLO3NNOO 9 2 155 20 06 0492 LYVd SS3NHVH 318V1 NOLLVNINH3L 20 06 0492 SSINYVH wona e Wi 970 Dras WMOd 3091 e Ti 321145 9 0 9 SISSVH2 1431 09 9 3X1 1081 HOLIMS 330 10 5 19 9 ___2 __ ___ 0
33. 1 gt POLARIS Specifications NOTES 1 gt POLARIS General Information CHAPTER 2 General Information RACING NOME Onstage EPI 2 2 POLARIS RACING DEPARTMENT 2rd aei ee nna a dates ete 2 2 2008 690 10 RACER MODEL 5 segre DE and qua d 2 2 OVER V 2 2 BREAK IN rr 2 2 2009 6000 uo rupe deb N eee ats M en aid 2 2 OVERVIEW 2 2 SNOWMOBILE NUMBER 5 2 0 2 3 MODEL NUMBER DESIGNATION Desi ios 2 3 VEHICLE IDENTIFICATION NUMBER 2 4 TONNE DECAL cta See masaqa te ketenes 2 4 VIN NUMBER DESIGNATION 2 4 PUBLICATION PARTNUMBER S un me ee a oe ele 2 4 2009 PUBLICATIONS a uy ara 2 4 ENGINE DATA FORMULAS 2 5 COMPRESSION PATIO 1 ds dice Did a ML 2 5 COMPRESSION RATIO EXAMPLE a 2 6 HEAD CC 2 6 PORT OPENING DURATION c3 2 6 TORQUE CONVERSION aiui ei 2 7 US TO METRIC iste Sach 2 7 GENERAL REFERENCE e SOC Ed x es 2 8 STANDARD BOLT TORQ
34. 1 365 Engine Service Specifications All Engines Cylinder Head Warp Limit 006 015mm Cylinder Taper Limit 002 051mm Cylinder Out of Round Limit 002 051mm Main Bearing Interference Fit RR 001 002 026 051mm Racer 0014 0024 036 061mm Connecting Rod Side Clearance 0114 0295 289 749mm Crankshaft Runout Deflection Limit 0025 07mm WINNING PERFORMANCE gt POLARIS and Coolinq Systems ENGINE INSPECTIONS Cylinder Head Inspection Using a flat bar and feeler gauge inspect each cylinder head for warping Replace head if warping exceeds 003 08mm Cylinder Head Warp Limit 006 015mm Cylinder Measurement Inspect each cylinder for wear scratches or damage If no damage is evident measure the cylinder for taper and out of round with a telescoping gauge or a dial bore gauge Measure the bore 1 2 from the top of the cylinder in line with the piston pin and 90 to the pin to determine if the bore is out of round Repeat the measurements at the middle and bottom of the cylinder Use the chart below and record all measurements Cylinder Measurement Worksheet Middle Bottom Taper Limit 002 051mm Out of Round Limit 002 051mm Crankshaft Runout Inspection SUPPORT SHAFT AT TWO ARROWS Support the crankshaft In a set of V blocks as shown Use a dial indicato
35. 28 18 24 16 24 14 20 13 ss Formula Gallon 128 Ounces e 128 Desired Ratio Ounces of oil for every 1 gallon of fuel e 128 20 20 1 Ratio 6 4 ounces of oil for every 1 gallon of fuel Always mix ratio in 5 gallon increments 2 8 Gasoline Volatility AMBIENT AiR TEMP RANGE CLASS PRESSURE HIGH 60 110 F A 7 0 psi 0 5 bar 16 C 43 C 50 F 9 0 psi 0 6 bar 10 C MAXIMUM REID VAPOR 110 F 43 C 40 E C 10 5psi 0 7 bar 4 C 97 F 36 C 30 5 12 0psi 0 8 1 85 F 29 13 5psi 0 9 bar 69 F 21 2 45 F for each 1000 ft 305m above sea level When gasoline is blended it is given a Reid Vapor Pressure RVP number which reflects its ability to vaporize or mix with air at a given temperature range Gasoline vapor pressure 15 measured by putting a sample of fuel inside a closed container and applying a specified amount of heat to the container for a certain amount of time RVP will vary from about 7 0 PSI during the summer to approximately 13 5 PSI during the colder months Service stations selling a large volume of fuel will normally have the correct blend to work well at all times throughout the year in their local area When the weather is very cold gasoline must be able to vaporize very quickly in order for an engine to start and warm up properly If summer blend
36. I C I C Cooling System Fluid Level Heat Exchangers T1 E T1 T1 E gt 99 1213 alee E 99 zi e lt un E ct J mm amp lt lt E el z 2 5 5 de vnl ct 5 2 SAE 09 Un un lt un em Hose Condition Routing JAHE TEE it cia lt S gt Re Bas has 215 o2 z lt E 5 E 5 z5 un un e Idle RPM Carburetor Adjustments u 3 1919 9 lt SESE Q Q c e lt m WINNING PERFORMANCE gt POLARIS 5 Maintenance Periodic Maintenance Table 600 RR 600 IQ Racer Item 150 mi 500 mi 1000 mi 2000 mi Pre Season 240 km 800 km 1600 3200 km Fuel Vent Hoses Or 1 1 or Fuel Filter Throttle Position Sensor Oil Hoses Oil Filter E Electrical System Auxiliary Shut Off Tether Switch 3 T T 4 j r r Y vv L r aa L Lubricate 1 Inspect or Adjust R Replace Clean
37. Install the chassis flange at the driven clutch side of the jackshaft Torque the flangette fasteners to specification 7 Loosen the chain tensioner 8 Remove the chaincase cover 10 Remove Lower sprocket and chain Jackshaft Flange Nuts 11 Remove the driveshaft bearing housing 17 ft lb 24 Nm 12 13 With the sled over on its left side and the rear skid removed remove the drive shaft Remove the rear suspension 3 Install the upper gear lower gear and chain into the chaincase 4 Torque the lower gear fastener to specification 14 Assemble in reverse order Follow Torque values as outlined in Chaincase Installation earlier in this chapter Lower Gear Fastener 19 ft lb 26Nm 5 Torque the upper gear fastener to specification Upper Gear Castle Nut 50 ft lb 68Nm 6 Insert the cotter pin and bend the edges around the nut flats 7 Adjust the chain tensioner until there is 25 375 6 95cm chain deflection gt POLARIS Drive and Systems BRAKE SYSTEM Overview The Polaris snowmobile hydraulic brake system consists of the following components or assemblies brake lever master cylinder hydraulic hose brake caliper slave cylinder brake pads and a brake disc which is secured to the drive line When the hand activated brake lever A is applied it contacts a piston B within the master cylinder As the master cylinder piston move
38. L SdlAV QU 34 N9 Ng Ng 1 m NEUE T ac aus mal 41083108 1140 1 24 14 80123135 JAANI N S T B 1102 dNV1 YOSNISOWUSHL 4350 LON BB ATTE e 1102 535 10 78 KE WO 1102 39 2 SIL 05 35 dN31 0 OL 19 SWHO 0170 NMONG OL MOT113A S81 Q3U 3LIHM OL JLIHM 9 0 N3349 01 3018 39NY151538 80102 JoNVISIS3H 2 00 1V 19 1 1 34 1102 10123135 JA802 ONINII 45 45 4018 102 T NOLLIN9I 430 1 fils 1 lI XR V SdV2 801 SWHO 01 Re Qv31 9014 01 Qv31 9014 8340 0731 AYVGNOD3S OL X2V18 SWHO JLIHM 01 2v 18 Su0102 JOVYL NIVN 402 F 39NVISIS38 1102 NOILINSI Ten NMOHS 38V SU0102 381M OML Ng ________________________ Mona O 3 0 80601 lt f M GNVH SS3NUVH Gaana 13 004 SWHO HO LIMS QU 8 6 4 __ 5 EN N3389 waya N33U9 1H9 1 N9 jd ng m 145012 ATIVNSON JN AES ______ 49 90 N p Un HOLIMS GNNOYD SISSYHO 3318 MY 80 H9IH M3AHVMONVH 3118 1H911 09 basa yv 18 39138 09 043931 80107 3UIM GNAOYD ANIONI No MO 1 04 34 9 HOLIMS 31 98 LV
39. Racer RR Front and Rear Torque Arms FRONT TORQUE ARM BUSHING ARM SHAFT MOUNTING ARM REAR TORQUE ARM SHOCK ROD CARRIER WHEEL SLEEVE Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table A 45 55 Ft Lbs 61 75 Nm 12 Ft Lbs 16 Nm A CAUTION C 25 Ft Lb 34 Nm 35 Ft Lb 47 Nm The fasteners securing the rear suspension to the Front Track Shock Fasteners 35 Ft Lbs 47 Nm tunnel are pre coated with a locking agent when new Rear Track Shock Fasteners 25 Ft Lbs 34 Nm Never re use these fasteners when removed Always use new pre coated fasteners when mounting the Assembly Notes suspension to the tunnel Never re use Nylock nuts Always replace with new parts All pivots must rotate freely after tightening fasteners POLARIS 8 13 Steering and Suspensions REAR SUSPENSION OPERATION Operation The primary function of the suspension 15 to provide a comfortable ride in all types of riding conditions It separates the rider from the ground while allowing for complete vehicle control The rear suspension also must provide weight transfer and maintain track tension Rear suspensions have many adjustable features for fine tuning to achieve optimum comfort The suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions However suspension adjustments
40. Systems IQ Racer Recoil Magneto RETURN SPRING RATCHET GUIDE RECOIL MAGNETO COVER RECOIL HUB 42 pA 6 N FRICTION PLATE INK SPRING RATCHET 2 MAGNETO STATOR Y FLYWHEEL NUT 9 Ft Lbs 12 Nm B 5 Ft Lbs 7 Nm 90 Ft Lbs 122 Nm D 12 Ft Lbs 16 Nm Apply Loctite 242 Apply Loctite 242 Disassembly Assembly Process 1 Remove the exhaust pipe and resonator If the recoil assembly does not require attention the recoil rope can remained attached to the handle If recoil component work is desired reference the Recoil Assembly section See Recoil Assembly on page 5 10 3 Remove the recoil magneto housing cover The recoil assembly is located inside the housing 4 Remover the recoil hub from the flywheel Secure the WINNING PERFORMANCE gt POLARIS 2 FLYWHEEL flywheel with a strap wrench PN PU 45419 Remove the flywheel nut and washer 5 Using the flywheel puller tool PN 2871043 insert the puller s three screws into the flywheel NOTE Do not thread the puller screws into the magneto stator located behind the flywheel 6 Turn the puller center bolt in until the flywheel pops off of the crankshaft 7 Mark the location of the magneto stator plate in several places using a scribe 8 Remove the magneto stator from the crankcase Assembly is reverse of disassembly
41. TANK BRACKET RACER ONLY RESONATOR BRACKET PIPE BRACKET SNOW FLAP TUNNEL GRIPPER FRONT FUEL TANK BRACKET 10 2 WINNING PERFORMANCE POLARIS Chassis Footrest Structure UPPER FOOTREST CLUTCH GUARD ASSEMBLY eee 10 3 Chassis CONSOLE AND SEAT Console Assembly View TETHER SWITCH 0 CONSOLE SIDE PANEL STRAP Seat w SEAT ASSEMBLY TAIL LIGHT SEAT WEDGE 1 0 4 WINHING PERFORMANCE POLARIS Chassis HOOD Hood Assembly View WINDSHILED TACHOMETER ASM FOAM INTAKE FOAM SEAL HOOD RETENTION BRACKET NOTE TORQUE FASTENERS HAND TIGHT ee ee 10 5 Chassis Hood Mounting and Bumper BUMPER NOTE TORQUE FASTENERS HAND TIGHT 1 0 6 WINNING PERFORMANCE POLARIS Chassis NOSEPAN AND SIDE PANELS Assembly View LH FENDER 4 SKID PLATE SINNING TERTORMANTE 1 0 7 gt POLARIS Chassis NOTES 1 0 8 WINNING PERFORMANCE POLARIS ELECTRICAL SYSTEMS CHAPTER11 ELECTRICAL SYSTEMS ELECTRICAL SPECIFICATIONS 11 2 SPARKPLUG 11 2 IQ RACER STATOR SPECIFICATIONS 11 2 IQ RACER COMPONENT MARKINGS 11 2 600 RR STATOR SPECIFICATIONS 11 2 600 RR COMPONENT MARKINGS
42. URS E LUE 8 10 SPHERICAL BEARING REPLACEMENT 8 10 UPPER LOWER CONTROL ARM REMOVAL 8 10 UPPER LOWER CONTROL ARM INSTALLATION 8 10 REAR SUSPENSION ASSEMBLY 5 8 11 2008 RACER RR PIVOTS AND REARIDLER 8 11 2008 RACER RR RAIL ASSEMBLY s dte Sube boe itle 8 12 2008 RACER RR FRONT AND REAR TORQUE 5 8 13 REAR SUSPENSION OPERATION cutke 9 Cb tos 8 14 OPERATION 8 14 8 14 COUPLING os raea 8 14 REAR SUSPENSION 8 15 ADJUSTMENT PROCEDURE an nE 8 15 REAR SUSPENSION RIDE HEIGHT EA 8 15 SCISSOR STOP ADJUSTMENT eese Uhr PU aaro as p Sm 8 15 EIMITERCSTRAP ADJUSTMENT 8 16 TORSION SPRING ADJUSTMENT 8 16 RAIL SLIDERS 8 16 WEAR Me Le 8 16 umaka quta 8 16 maw Sama ee UE BA ree zq 8 17 REAR SUSPENSION REMOVAL AND 8 17 EMO VA CN dh EE 8 17 INSTALLATION
43. VOLUME cc DISP CYLINDER DISPLACEMENT cc R COMPRESSION RATIO I ___5 __ S FULL ENGINE STROKE DISP x 25 4 I INCHES PER cc OF IHV B CYLINDER BORE cm 3 1416 DISP PI x B x S WINNING PERFORMANCE 2 POLARIS 9 General Information Compression Ratio Example Bore 6 5cm Stroke 6 0 cm IHV 17 1cc Displacement 3 1416 PI x 42 25 Bore squared x 6 0 stroke 4 199 098cc Displacement 199 098cc R 17 1 199 098 17 1 12 643 Full Stroke Compression Ratio To calculate the Effective Compression Ratio substitute the exhaust port height for the stroke in the formulas above Exhaust 2 95cm exhaust port height is 29 5mm Effective Displacement 3 1416 PI x 42 25 bore squared x 2 95 exhaust port height cm 4 97 89 Effective Displacement 97 89cc Effective Compression Ratio 17 1 cc 97 89 Effective Displacement 17 1 cc 6 725 Effective Compression Ratio 6 725 In order to increase the Full Stroke Compression Ratio to 13 6 how much material do you need to remove from the cylinder head You know that R IHV Displacement IHV and you want to find out IHV Displacement 199 098cc and we want R to 13 6 so then desired Displacement 199 098 R 13 6 1 12 6 desired 15 801 desired IHV to have 13 6 1 Full Compression Ratio Head cc Removal Example The total number of cc s
44. When the throttle opening becomes greater and the area between the needle jet and jet needle increases fuel flow is metered by the main jet The number on the jet indicates the amount of fuel which will pass through it in one minute under controlled conditions Larger numbers give a greater flow resulting in a richer mixture Main jets are screwed directly into the needle jet base MAIN JET Jetting Guidelines Changes in altitude and temperature affect air density which 1 essentially 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 4 6 Verify the production setting for your specific model All carburetors must be re calibrated if operated outside the production temperature and or altitude range The main jet installed in production is not correct for all altitudes and or temperatures Refer to the jetting cart in the Specifications Chapter of this manual for correct jetting for altitude temperature ranges NOTE It is the owner s 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 main jet always use the lowest elevation and temperature that is likely to be encountered
45. aus IS 5 28 THERMOSTAT 5 29 THERMOSTAT ORIENTATION auod ote og ot 5 29 C POLARIS and Coolinq Systems ENGINE SPECIFICATIONS Component Torque Sequences Fastener Torque Guide Cylinder Head Torque Pattern Spark Plug m Apply Nyogel 25 Ft Lbs 70 In Lbs 8 Nm 168 In Lbs 18 FLLbs 2 Temp Sensor 24 NM ida 9 e v _ 05 C 9 EV Bellows Nut Jo MAG PTO Bleed Screw Oe Cylinder N A 37 Ft Lbs Nuts 50 Nm 42 Ft Lbs 9 22 Ft Lbs 7 Ft Lbs Water Pump 9 Ft Lbs Cover 12 9 8 9 90 Ft Lbs Flywheel Nut 122 Nm Loctite 242 12 Ft Lbs 5 Ft Lbs Crankcase M6 9 Ft Lbs 12 Nm Loctite 242 M8 22 Ft Lbs 22 Ft Lbs 30 Nm 30 Nm 30 Ft Lbs 45 Ft Lbs Engine Straps 41 Nm Loctite 242 Impeller 10 Ft Lbs 13 Nm 5 2 eee POLARIS 600 RR Crankcase Torque Pattern Engine and Cooling Systems Engine Specifications PISTON TO INSTALLED HEAD PISTON RING END TRIGGER TO ENGINE MODEL HEAD SQUISH CYLINDER VOLUME GAP FLYWHEEL GAP NUMBER INCHES MM CLEARANCE CC INCHES MM MM INCHES MM 050 060 004 006 014 020 S 3649 6044 PU6F 27 6 28 9 1 283 1 544 105 159 36 508 4 8 030 046 0034 005 014 022 S 3577 6044 PU6J 24 26 765 1 16 088 129 36 56 135
46. brake lever a few times and hold it again 9 Repeat steps 7 and 8 until new brake fluid can be seen coming from the caliper bleeder fitting or if bleeding air repeat this step until only fluid is seen coming out This may take several intervals Bleeder Screw 8 11 Ft Lbs 11 15 Nm 11 When adding fluid add DOT 4 brake fluid to 1 4 5 16 6 8 cm from the reservoir top 12 Install cover and diaphragm assembly 13 Tighten the cover screws to specification Cover Screws 6 8 In Lbs 7 9 Nm 14 Field test machine before putting into service Check for proper braking action and lever reserve Lever reserve is when the lever is firmly applied the lever reserve should be no less than 1 2 1 3 cm from the handlebar 15 Verify that the sight glass indicates a full reservoir 16 Check brake system for any fluid leaks 7 12 Master Cylinder Lever Service COVER SCREWS A Banjo Bolt 240 264 In Lbs 27 29 Nm B Cover Screws 6 8 In Lbs 7 9 Nm C Handlebar Clamp 60 80 In Lbs 6 7 9 Nm To remove the brake lever remove the e clip from the lever pin Extract the pin from the housing then remove the lever Disconnect the brake hose from the master cylinder assembly The master cylinder assembly is not serviceable Master cylinder reconditioning requires complete replacement Refill and bleed the brakes system as outlined in this chapter See Brake Fluid Replac
47. fuel is being used in the winter little or no vaporization will occur Droplets will form causing flooding and very hard starting If winter blend fuel is being used during the summer months it may cause vapor lock boiling fuel inside the fuel lines fuel pump or carburetor This will cause warm engine drive ability problems and hard starting when warm H IN G P E H FORMANCE POLARIS General Information SAE Tap Drill Sizes i cu e 2 MONS 1 32 0312 1 mm 0394 BCA eee were Rise eed 0469 28 27 64 5 64 ees 0781 2mm 0787 1 2 20 29 64 ______ 0938 9 16 12 31 64 7 64 1094 3 1181 9 16 18 3364 2 5 1250 5 8 11 17 32 1200 5 8 18 777 5 32 1563 4 1575 11 04 1719 3 4 10 2 32 D am 1875 5 1969 3 4 16 11 16 bu See 2031 7 8 9 4964 2188 7 8 14 13 16 15764 2s sce eee eee 2344 6 mm 2362 DELL PEE k a NCA NN EISE 2656 7 mm 2756 12 29w94 BOLA du ore D ust 2813 1 1 8 7 63 64 assis 2969 1 1 8 12 1964 5 16 3125 8mm 3150 1 1 4 7 1 7 64 BU OE asas te pua sii 3281 1 1 4 12 1 11 64 1 1 2 6 1 11 32 3 8
48. iagrams D iring W 2008 IQ 600 RR Hood Harness WIRES ARE REPRESENTED BY SOLID OR DASHED LINES TO SIMPLIFY TRACING IN DIAGRAM WIRE COLOR LEGEND ENGINE GROUND CHASSIS GROUND GY GN DG DARK GREEN oc HARNESS 2410912 02 YE TWO WIRE COLORS ARE SHOWN WITH MAIN TRACE COLORS EXAMPLE RD YE RED WITH YELLOW TRACE ACC HEADLAMP 1 YE RD LEFT HEADLAMP 2 06 20 06 RIGHT HEADLAMP 16 ACC LAMP STANDARD ON IG SHIFT LOW OIL INDICATOR HIGH BEAM INDICATOR XS YE RD BN JUMPER 2410902 STANDARD ON 600 RR NOT REQUIRED ON SHIFT 01 YE RD 03 BN s 1 BN 13 YE RD 4 06 SPEEDOMETER REVERSE HOT LAMP amp TACH ACC CHASSIS HOOD 08 BK WH 01 W 1 06 05 VT NOTE IF VEHICLE HAS SPEEDOMETER USE PART NO 2410931 JUMPER 2 IF VEHICLE HAS TACHOMETER USE PART NO 2410902 JUMPER WIRE TERMINATION TABLE CCT COLOR GAUGE FROM CONNECTOR CAVITY TO CONNECTOR CAVITY Ol YELLOWRED 16 CHASSIS HOOD 1 LEFT MEADLAPP 02 DK GREEN 16 CHASSIS HO00 2 LEFT HEADLAPP 03 BROWN 16 CHASSIS HOOD 3 BEADLAPP 04 ORANGE 20 CHASSIS HO00
49. leak out 3 Pinch both cooling hoses then remove from caliper Remove the caliper assembly from the chaincase Caliper Assembly 1 Replace caliper bolts and torque to specification Caliper Bolts 18 20 Ft Lbs 24 27 Nm 2 Reconnect the cooling hoses 3 Place the brake hose on the caliper in the same orientation as it was before it was removed 4 Clean the threads of the banjo bolt and the threads in the caliper 5 Follow Brake Line Replacement See Brake Hose Replacement on page 7 13 6 Install banjo bolt into the caliper and torque to specification 7 Bleed the brakes See Brake Fluid Replacement amp Bleeding on page 7 11 8 liquid cooled caliper bleed the cooling system of any trapped air Brake Pad Replacement Brake Pad Brake pads need to be replaced if the total thickness of the pads and backing are less than 250 6 35mm Remove brake pad retaining pin Remove the brake pads Inspect the brake disc for any wear pu UE Replace brake pads in reverse order of removal 250 6 35mm Brake Disc Replacement The brake disc should be replaced if the thickness of the disc is below 193 49cm Remove the chaincase Slide the brake disc from the jackshaft Check the jackshaft for any damage Replace the o ring on the jackshaft Replace the brake disk Assemble the chaincase pu Sede d 7 13 Drive and Systems NOTES 714 s Stee
50. of rope through the notch in the pulley Prevent the rope from being retracted by tieing a knot in the rope on the outside of the housing at the rope guide hole Wind the recoil pulley counterclockwise until the spring begins to bind Unwind the pulley clockwise two revolutions Pull on the rope to disengage it from the notch in the pulley Un tie the knot in the rope and allow it to retract into the housing Pull on the handle to verify proper operation PERFORMANCE gt POLARIS Engine and Cooling Systems ENGINE REMOVAL AND 9 Separate the carburetors from the intake boots and secure INSTALLATION it out of the way Removal v d DINE PS 4 s y ki K 1 Remove the and side panels Disconnect exhaust pipe sensor and remove the exhaust system 3 Turn the fuel valve to OFF 4 Remove the drive belt 5 Remove the drive and driven clutches NOTE Keep track of the spacers that are on the E 7 8 Remove the exhaust system NOTE Grey colored springs are located on the header pipe and should be replaced in the same area dc 5 11 Engine and Cooling Systems 12 Remove the fastener that holds the torque stop to the engine plate 13 Disconnect the spark plugs 14 Drain all coolant from the engine 15 Remove the lower center front cooling hose 16 Remove the hose from the top of the therm
51. peak performance 3 Always use 92 octane fuel the required racing fuel based on the level of engine and ignition modifications 4 Always use Polaris Racing Oil Pre mix 20 1 during the break in period then 32 1 for normal operation 5 Always break in a new or rebuilt engine to ensure durability 2008 600 RR MODEL Overview The 2008 600 RR snowmobile shares many of the same race proven features found on the 2008 600 IQ racer model Some of the most significant differences are 600 RR engine bore x stroke 77 25 x 64mm 600 Racer engine bore x stroke 73 x 70mm 600 Racer requires 92 octane fuel 600 RR calibrated for 91 oxygenated fuel 600 RR front suspension is narrower than Racer Trail Legal 600 RR features less aggressive front and rear suspension shock valve configurations and torsion springs 600 RR features PERC 600 Racer uses Dragon pipe heater ignition system 600 RR uses larger 9 gallon fuel tank 600 RR uses TM38 carburetors Racer uses TMAOSs 600 RR utilizes oil injection 600 Racer requires pre mixed fuel WINNING P E H FORMANCE POLARIS General Information SNOWMOBILE NUMBER DESIGNATIONS Model Number Designation Example SOSMX6FS MODEL OPTION MODEL LINE MODEL TYPE ENGINE MODIFIER VIN IDENTIFIER YEAR IDENTIFIER 2 3rd digit digit digit ehdgr digit 7th digit digit
52. race of the new bearings and press them into the chaincase from the snap ring side NOTE Press on the bearing outer race only or damage may occur to bearing 7 Replace the snap rings 12 18 8 Press in new seals 14 15 in the back of the chaincase until the outer edge of the seal is flush with the chaincase shoulder 7 7 Drive and Systems DRIVESHAFT AND JACKSHAFT Assembly View A DRIVE BELT 0 OFFSET WASHERS SET SCREW BEARING FLANGE 2 FLANGE GASKET JACKSHAFT BRAKE DISC ae RETAINING RING 2 SPACER RR DRIVESHAFT va CS O RING 2 lt lt A gt SPACER lt Nh es k f o JE i x 1 NEN GO ea RACER DRIVESHAFT NOTE Set driven clutch offset following procedure in the PVT System Chapter Lubricate components as outlined in the Periodic A Driven Clutch Fastener 17 Ft Lbs 23 Nm Maintenance Table B Jackshaft Flange Nuts 17 Ft Lbs 23 Nm Tighten chaincase mounting nuts using a criss C Driveshaft Housing Nuts 17 Ft Lbs 23 Nm cross pattern D Chaincase Mounting Nuts 28 Ft Lbs 38 Nm Install jackshaft driveshaft seal sleeve with beveled edge towards brake disc then install o ring inside sleeve A CAUTION Racer slip driveshaft components serviceable 7 8 WINNINO PERFORMANCE gt POLARIS Drive and
53. required 10 64 1321585 CAUTION 05 1321884 08 1322427 Never shim drive clutch spring to Increase its compression 10 70 NEN NEN 1322414 rate This may result in complete stacking of the coils and subsequent clutch cover failure 1322428 oa 1322429 76 1322585 1076 1322586 11 Series Weights WEIGHT GRAMS 89 PART NUMBER 11 40 1322593 11 42 1322592 11 48 1322590 11 50 1322589 11 52 1322595 Drive Clutch Weights Full Tail Weights weem PARTNUMBER S43H 1321849 S45H 1321850 S47H AM 1321851 S49H AN 1321730 S51H 1321731 S53H 1321759 S55H 1322004 11 64 1322604 11 66 1322559 11 68 1322558 11 70 1322523 11 72 1322524 11 74 1322525 11 76 1322526 6 6 WIMNINSG POLARIS PVT System PERC Team LWT Driven 24 Fin PERC Team Driven Helixes 12 Fin 9133773 62 42 46 DESCRIPTION 64 42 36 64 38 25 56 42 36 9135503 54 38 25 5135504 S36 5133784 58 40 46 5135772 66 44 46 5133785 62 40 46 5133786 62 44 46 Non PERC Team LWT Driven Helixes 24 Fin B CE CNET PART NUMBER DESCRIPTION 2122055 5133789 60 46 46 62 40 46 64 40 55 5133886 54 42 46 64 38 65 5134095 56 42 36 5135376 5134226 60 42 75 a 5134263 _ 54 38 25 o 62 40 4
54. shock shaft T for damage Replace shock shaft if damage is found ining bolt 25 30 ft Ib 34 41 N m Piston retaining bolt 25 30 ft lb 34 41 N m 8 If required replace the bearing seal 7 and o ring 8 Walker Evans Air Shock Assembly 1 Place the specified amount of fluid into the shock body CAUTION Do not overfill the shock oil level Too much shock oil may cause the shock rod to hydro lock 2 Insert and torque down the bearing cap 4 assembly into the shock body 9 Bearing Cap Torque 85 ft lb 115 N m CAUTION Do not over torque the shock rod bearing cap or shock performance will be compromised 3 Flip shock over in the vise so that the shock rod is facing downward 4 Pressurize the shock to 170 psi 11 7 bar Hold the fill tool needle in the port for thirty seconds to allow the nitrogen gas to stabilize IMPORTANT Never re insert the fill tool needle back into the shock to check pressure after initial charging The amount of gas required to fill the tool will give a false pressure reading Always completely discharge the shock and refill to 1 Place the body cap 1 of the shock in the vise so that the obtain an accurate pressure reading shock rod 2 is facing downward 5 Check for any leaks 2 Remove the service port screw 3 and release the pressure with the shock charging needle Verify all pressure is released 3 Place the body cap 1 in the v
55. should be measured for excessive taper and out of round Replace rings if the installed end gap exceeds the service limit Always check piston ring installed gap after re boring a cylinder or when installing new rings Keystone Piston Ring Cutaway Piston rings are installed with marking or beveled side up WINNING PERFORMANCE C POLARIS Bearing Fit Any time crankshaft bearing failure occurs and the case is reused check the bearing fit into the case halves using the following procedure With case halves cleaned press a replacement bearing into each of the main bearing journals to determine a basic amount of press fit Do a comparison check of all journals by manually forcing the bearing into the bearing seats noting if any are noticeably loose or tight Normal hand installation will be an indication of the recommended interference fit If the bearing falls out of the case when the case is inverted or if the crankcase bearing surface is severely galled or damaged the crankcase assembly should be replaced Main Bearing Interference Fit 001 002 026 051mm Racer 0014 0024 036 061mm Main Bearing Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris engine oil Carefully check each main bearing on the crankshaft Due to extremely close tolerances the bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Tu
56. speed PERFORMANCE gt POLARIS Engine and Cooling Systems Checking Crankshatt Index I Remove the drive belt and drive clutch Securely fasten a large degree wheel on the flywheel end of the crankshaft Make sure that it is mounted concentrically with the crankshaft center line With a section of wire wire coat hanger anchor it to a convenient spot Bend one end at the outer perimeter of the degree wheel as shown below Install a dial indicator into the magneto end cylinder spark plug hole The ignition timing is referenced by the magneto end Locate TDC as accurately as possible by finding the center of the point where there is no piston movement note the Zero the dial indicator at this point Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads 100 2 54mm after top dead center 100 Cylinder The cylinder bore must de glazed whenever new piston rings are installed A light honing with fine stones removes only a very small amount of material A proper crosshatch pattern is important to provide a surface that will hold oil and allow the rings to seat properly If the crosshatch 1 too steep oil retention will be reduced A crosshatch angle which is too shallow will cause ring vibration poor sealing and overheating of the rings due to blow by and reduced contact with the cylinder
57. the moveable sheave s Notice as the spider seat location is changed the sheave marks made before disassembly no longer align C There are two ways to bring the sheave marks into alignment 6 18 Vary the amount and thickness of spacer washers washer thickness may vary slightly Re index marked spider leg to another tower This can be done because spider has little effect on overall clutch balance Re indexing the spider 1 3 turn clockwise or 1 leg will allow the realignment of the moveable and stationary sheaves as previously marked D For EXAMPLE 0 020 or 0 032 0 5 0 8mm washer removed re index spider clockwise 1 3 turn NOTE Alignment marks on the sheaves should be with in 1 25 4mm after final assembly and torquing gt POLARIS PVT System Drive Clutch Installation NOTE Always clean the clutch taper before re installing clutch on engine 1 Place a clutch taper reamer PN 2870576 In a vise and lubricate the cutting edges with cutting oil Clean the clutch taper by manually rotating the clutch clockwise on the reamer one or two revolutions Only use the weight of the clutch and do not push down on the clutch while turning 2 Check crankshaft taper for galling or scoring If necessary clean the taper evenly with 200 grit emery cloth 3 The clutch taper and the crankshaft taper should be clean and dry Do not use harsh cleaners whic
58. to 15 C to 20 F 18 C to 7 C 15 F to 35 F 9 C to 2 C 30 F to 50 F 1 C to 10 C gt 60 F gt 16 C 470 460 450 430 420 400 390 370 4 3 3 3 2 4 360 45 F to 65 F 7 C to 18 C 0 600 0 2000 Displacement Cylinders 99 2 Bore inches mm 3 04 77 25 Stroke inches mm 2 52 64 Piston to Cylinder Clearance 004 006 105 159 inches mm 014 020 036 508 inches mm Operating RPM 200 9100 Idle RPM 1500 Engagement RPM 200 4700 Exhaust Valve Spring NO m dt E P 4 m c gt UJ UJ 600 1200 2000 4000 95 95 N No t m m 1200 1800 4000 6000 Oo Oo 99 J Oo O2 Oo Oo gt 1800 2400 6000 8000 52 W 5 52 52 gt 52 gt 2400 3000 8000 10 000 UJ 3000 3700 10 000 12 000 5 5 Dm 5 Y 5 Zi c When using non oxygenated fuel with a RON greater than 93 decrease the main jet number in the above chart by 10 and raise the Carburetor Settings E clip one position If the chart recommends clip 1 install washer on top when using RON 93 Settings Pilot ti _ meters Shift Clutch Clutch Driven Jet
59. to the specifications at the beginning of the chapter Use the correct torque sequence when tightening the screws 5 25 Engine and Cooling Systems Variable Exhaust System VES uy m 2 SOLENOID n ie Jj SOLENOID VENT HOSE VENT HOSE IQ RACER SOLENOID ASSEMBLY GASKET GUILLOTINE d S HOSE TO EV gt HOSE TO EV HOUSING HOUSING COVER BELLOWS NUT FITTING BELLOWS HOSE TO EV HOSE EV VENT HOSE A 12 Ft Lbs 16 Nm B 16 Ft Lbs 22 Nm C Hand Tight Apply Pipe Sealant Disassembly Assembly Process 1 Remove the two left and right screws from the housing cover These screws secure the housing to the cylinder 2 Carefully pull the assembly out of the cylinder Discard the gasket 5 26 600 HO SOLENOID ASSEMBLY 3 Remove the remaining two screws from the cover AX CAUTION 4 Inspect the spring and replace if abnormally worn or damaged 5 Inspect the bellows for cuts or deformation Thoroughly clean the guillotine using a solution of warm soapy water and a Scotch Brite pad 6 Assembly is the reverse of disassembly Always use new gaskets during assembly NOTE Do not over torque the bellows nut or housing screws WI HH PERFORMANCE C POLARIS Engine and Cooling Systems COOLING SYSTEMS 2008 IQ 600 RR REAR TUNNEL COOLER LIQUID COOLED BRAKE HOSE TO ENGINE FROM TU
60. with waxes and rust inhibitors grease oil or paint If the machine is equipped with a battery disconnect the battery cables and clean the cables and battery posts Fill battery to proper level with distilled water and charge to full capacity Remove and store the battery in a cool dry place The machine should be stored in a dry garage or shed out of the sunlight and covered with a fabric snowmobile cover Do not use plastic to cover the machine moisture will be trapped inside causing rust and corrosion problems Clutch And Drive System Remove drive belt and store in a cool dry location Lubricate sheave faces and ramps of drive and driven clutches with light oil or rust inhibitor All lubrication applied as a rust preventative measure must be cleaned off before installing belt for service and operating machine Controls And Linkage All bushings spindle shafts and tie rod ends should be coated with a light coat of oil or grease Throttle controls and cables should be lubricated Force a small amount of lubricant down cables Electrical Connections Separate electrical connector blocks and clean corrosive build up from connectors Lubricate or pack connector blocks with Nyogel grease and reconnect Replace worn or frayed electrical wire and connectors 3 14 Carburetor Throttle Body Fog engine with Polaris Fogging Oil aerosol type according to directions on can Fuel System Treat the fuel system with Polar
61. x FK 54 1 1 Wes Ta oat nm ur 4 k RECOIL HANDLE RETURN SPRING RATCHET MAGNETO STATOR SPRING 41 FLYWHEEL E FLYWHEEL NUT RECOIL HOUSING 7 Mark the location of the magneto stator plate in several places using a scribe 8 Remove the magneto stator from the crankcase A 9 Ft Lbs 12 Nm 9 Clean the crankshaft and flywheel tapers with a solvent B 5 Ft Lbs 7 Nm Apply Loctite 242 Stator such as clutch cleaner C 90 Ft Lbs 122 Nm Apply Loctite 242 10 Assembly is reverse of disassembly Reference the fastener Di blv A blv P torque specifications at the beginning of the chapter 11 Do not use impact wrench to install the flywheel nut 1 Remove the exhaust pipe and resonator If the recoil assembly does not require attention the recoil rope can remained attached to the handle If recoil component work is desired reference the Recoil Assembly section See Recoil Assembly on page 5 10 3 Remove the recoil magneto housing cover The recoil assembly is located inside the housing 4 Remover the recoil hub from the flywheel Secure the flywheel with a strap wrench PN PU 45419 Remove the flywheel nut and washer 5 Using the flywheel puller tool PN 2871043 insert the puller s three screws into the flywheel NOTE Do not thread the puller screws into the magneto stator located behind the flywheel 6 Turn th
62. 0 8i T 199 3081 H211MS 440 10M 3MI9N3 2 71 11 7191 34 0009 id T owos sis mer 60 QNsd 905554 anoo ioo er 08 2 8i i 960 aon a es HEC en ee e 81 et ee annosa SISSVHO va e1 11 9115 SISSVH2 e1 T eeo L 031130 3NI9NS SISSYHD 109 ei 923 c v oasa 3NI9N3 SISSVH2 dim f sa wi 0 00 ows 3i Wl G31 10H 3 5155 0 e1 23 HOLINS _GOOH SISSWHD 30 oeo 01013105 A3 3NIDN3 SISSVH2 103 e1 23 HOLINS TG 620 1 11145 4 51550 4081 mi 920 102 w
63. 1 LIBERTY P Um F ie m lu a T 5 29 Engine and Cooling Systems NOTES 530 2 POLARIS PVT System CHAPTER 6 PVT System 6 2 OVERVIEW o su d 2 OES 6 2 DRIVE SPRING a wets ham ees yee ere Ga ee E t 6 2 CUTE WV tench ect setae eet o e E 6 2 NEUTRAL SPEED iudice er oil inet eed ee os 6 2 ENGAGEMENT RPM oh 6 2 SHIPTOUMOVERAREY dO eee les noa 6 2 ea ree pce ta ee See ee 6 2 DRIVEN SPRING 6 2 5 630 pas 6 2 FINAL GEARING Banke 6 3 TAN OUT lt bd ona Re he dona 6 3 HIGA RATIO o ete ee tet qa iu 6 3 RAMP le 6 3 GENERAL INFORMATION i poet ted rec tcx m PR d ga 6 4 TOOLS cr eee E dade O x 6 4 DRIVE ae 6 5 SPRING FREE LENGIR lt a Heuer rito un ee dB 6 6 DRIVE CLUTCH WEIGHT S2taetec tote nie t
64. 1 Place the shock rod in a vise so that the threaded part is facing upward 12 Place the valve stack on a clean shop towel in order of removal NOTE Place the valve stack on a clean shop towel in case you have to move them This will also help when assembling them back onto the shock rod gt POLARIS 13 Inspect the valves for kinks waves pits or foreign material 14 Inspect the piston wear band and replace if damaged or worn Walker Evans Remote Reservoir Piggy Back Shock Assembly 1 Secure the shock rod in a vise with the threads of the rod facing up 2 Place the compression valve stack on the rod in the reverse order of disassembly 3 Place the valve piston on top of the compression stack 4 1 4 Place a new lock nut onto the shock rod Torque the new lock nut to specification Lock Nut Torque 14 ft lb 19N m IMPORTANT Do not over torque or damage to the valve stack can occur WINNING gt POLARIS 12 Shocks Secure the shock body by its lower mount Set the compression damping adjustment selector to position 1 Fill the shock body and remote reservoir 1 2 full of Walker Evans 5w shock oil PN 2874522 Apply thin film of oil to the IFP o ring and floating wear band located on the shock rod piston Compress the wear band and insert the IFP into the reservoir Allow as much air as pos
65. 11 4 Ignition Timing Chart NOTE If a timing curve selector box is installed turn the selector knob to D 600 HO IQ 600 CARBURETED RACER ENGINE 22 128mm ROD 132mm ROD 64mm STROKE 70mm STROKE mm Degrees BTDC Inches 0 0061 0 0002 0 0067 0 0244 0 0010 0 0270 1 0 0003 2 3 0 0022 0 0607 4 5 0 0011 0 0024 4 04974 00038 01078 00042 7 5 0822 00060 0164 02066 6 02190 02086 0244 0005 _ 7 0 2979 0 0117 0 3298 0 0130 0 3889 0 0153 0 4305 0 0169 9 0499 00194 0545 02214 0264 0320 13 0 0403 1 1321 0 0446 14 0 0466 1 3115 0 0516 0592 0673 18 1 9487 0 0767 2 1569 0 0849 19 2 1681 0 0854 2 3996 0 0945 26547 01045 0 1750 0 1260 24 3 4300 0 1350 3 7958 0 1494 25 3 7146 0 1462 4 1106 0 1618 01747 0 1880 29 4 9558 0 1951 9 4835 0 2159 30 5 2911 0 2083 5 6543 0 2305 31 5 6361 0 2219 6 2358 0 2455 0 2609 02768 35 7 1099 0 2799 7 8652 0 3097 36 7 5010 0 2953 8 2974 0 3267 0 344 03518 gt POLARIS ELECTRICAL SYSTEMS IQ Racer Ignition Timing Curve Selector The optional ignition timing curve selector box PN 4010329 allows the operator to advance or retard the entire ignition timing curve by moving the selector knob to one of seven positions Dial Position Timing or LM Low Resistance Yellow to Black 4650 4850 6060 6320 0 980
66. 2008 600 RACER SNOWMOBILE SERVICE MANUAL FOREWORD This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference All references to left and right side of the vehicle are from the operator s perspective when seated in a normal riding position some procedures outlined in this manual require a sound knowledge of mechanical theory tool use and shop procedures in order to perform the work safely and correctly Technicians should read the text and be familiar with service before starting the work Certain procedures require use of special tools Use only proper tools as specified Comments or suggestions about this manual may be directed to Service Publications Dept Polaris Sales Inc 2100 Hwy 55 Medina Minnesota 55340 2008 600 RR IQ Racer Snowmobile Service Manual PN 9921088 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 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 p
67. 3 Nm Assembly Notes Install spindle bumper with flat side facing forward Replace wear bar carbide when damaged or when carbide edge 1s worn away Track Tension Track tension is critical for maintaining correct suspension operation If the track tension is too loose it may cause the track to slip or ratchet If the track is too tight it will wear down the rail slides reduce top speeds cause rear suspension vibration and cause track and rear suspension durability problems 3 12 1 Lift the rear of the machine and place jack stand or secure the rear of the machine so that the track is off of the ground 2 Start the engine and slowly let the engine turn the track over This will warm up the track for correct measurement 3 Shut off the engine Place a 10 lb 4 54kg weight at point A Point A is 16 41cm ahead of the rear idler shaft E 5 Measure the distance D between the rail slider and the track This measurement should fall with the measurement range for the appropriate vehicle see chart this page 6 If adjustment is needed loosen up the lock nuts B on each side Loosen up the idler shaft bolts F 8 Turn each adjuster bolt C clockwise to tighten track Turn the adjuster bolt counterclockwise to loosen track tension 9 Torque the lock nuts B and idler shaft bolts on each side to 35 ft lb 48 N m 1 1 4 1 1 2 3 1 3 8cm
68. 4 SPEEDOMETER 5 05 VIOLET 20 X CHASSIS HO00 5 SPEEDOMETER 2 06 YELLOW 18 CHASSIS HO00 6 AC POWER SPLICE 07 WHITE 18 CHASSIS HOOD 1 REVERSE HOT LAMP TACH 5 08 BLACK WHITE 18 CHASSIS HOOD 8 REVERSE HOT LAMP TACH ACC 2 09 YELLOW 18 SPEEDOMETER 3 AC POWER SPLICE 10 YELLOW 18 SPEEDOMETER 3 SPEEDOMETER 4 I BROWN 18 SPEEDMETER 180 12 BROWN 18 SPEEDOMETER 1 REVERSE HOT LAMP TACH ACC 4 13 YELLOWRED 20 SPEEDOMETER 16 ACCRHEADLAMPP B p e xml ccu Lc 15 YELLOW 18 REVERSE HOT LAMP 4 TACH ACC 1 C POWER SPLICE 16 BROWN 16 RIGHT HEADLAMP 180 f YELLOW 18 A AC POWER SPLICE 18 YELLOWRED 20 ACC HEADLAMP 8 RIGHT HEADLAMP 19 YELLOWRED 18 LEFT HEADLAMP RIGHT HEADLAMP 20 DK GREEN 18 LEFT HEADLAMP RIGHT HEADLAMP L 21 BROWN 18 LEFT HEADLAMP RIGHT HEADLAMP 2410931 STANDARD 10 SHIFT NOT REQUIRED ON 600 RR 1 STANDARD 600 ACCESSORY IQ SHIFT REVERSE LAMP TEMP LAMP INDICATOR INDICATOR 11 3 gt POLARIS WINNING iagrams D iring W 2008 IQ 600 Racer YSLSINOHOVL 1HOTIV L m 1 1HOITIV
69. 5 1 00 x 025 00 x 010 625 x 065 NOTE Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise eyelet down threaded end up POLARIS Shocks SHOCK MAINTENANCE WHEN USING COMPRESSED AIR TO DRY COMPONENTS PROTECTIVE EYE WEAR SHOULD BE WORN TO AVOID RISK OF INJURY Nitrogen gas is under extreme pressure use caution when releasing nitrogen gas from shock Protective eye wear should be worn to avoid risk of injury CAUTION Extreme caution should be observed while handling and working with high pressure service equipment Wear a face shield safety glasses and ear protection during service of these shocks Care should be observed while handling the inflater needle and pressure gauges Maintain your equipment and keep it in good working condition injury should occur consult a physician immediately Extreme cleanliness is of utmost importance during all disassembly and reassembly operations to prevent any dirt or foreign particles from getting into the shocks Keep the parts in order as they are disassembled Note the direction and position of all internal parts for reassembly Before servicing a gas shock it is important that all the gas pressure be discharged from the unit Refer to the instructions listed below for the proper procedure of discharging the gas pressure from a shock Protective eye wear should be worn to avoid risk of injury while servici
70. 6 64 40 55 5134507 58 46 46 74150 46 5134508 60 42 46 74 48 46 5134721 62 46 36 74 44 46 5134722 62 42 36 74 40 46 5134877 64 38 36 70 50 46 5135057 62 38 36 70 48 46 5135242 64 38 25 5135243 64 36 25 5135524 AG 5135243 64 36 25 66 50 46 2135525 66 48 46 5135256 64 42 36 66 44 46 66 40 46 5135276 64 42 46 9135537 64 38 65 5135480 5135486 5135521 5135522 5135523 LT PERFORMANCE f gt POLARIS 6 PVT System Non PERC Team Driven Helixes 12 Fin Team Ramp Angles PART NUMBER DESCRIPTION 66 44 46 70 48 36 74 48 46 SM 70 48 46 74 44 46 74 40 46 72 44 46 iem 72 40 46 70 44 46 gare 70 40 46 68 44 46 51 33495 68 40 46 Beginning angle steepest 3 Measurement of transition A owes angle B 5133496 66 48 46 66 40 46 The angles and length of the transition between the first and final 5133497 64 44 46 15 stamped the back of the helix The first number 64 40 46 designates the starting angle of the ramp The second number 62 44 46 designates the finish angle The last number is 9133498 62 40 46 transition distance in Inches between the starting and finish angles 58 44 46 58 40 46 66 44 46 CAUTION 70 44 46
71. 9th digit B Basic LX G 155 RMK H 163 RMK 08 2008 J 136 RMK 09 2009 K 144 RMK 10 2010 M 155 STD 11 2011 N 163 STD 1A 121 F C OHV 4 Cycle Fuji 3A 340 F C Piston Port 4B 488 L C Piston Port 5B 544 F C Cylinder Reed E Europe 6F 600 EV L C Case Reed M Military 12 2012 6H 600 EV L C Case Reed CFI R Rolling 6J 600 EV L C Case Reed Chassis 13 2013 Switchback WzMini Indy 7 750 Four Stroke S Standard 14 2014 Switchback 15 2015 Prem 7F 750 Four Stroke Turbo i 7J 700 EV Case Reed T louring 795 EV L C Case Reed CFI U Utility X Race Y Touring LTD digits that would transfer to 17 digit VIN and are used in digits 4 8 respectively Qth digit will be used on color featured versions of models not including the base First 3 digits and 9th digit are sued in model number only They are not used with the 17 digit VIN PERFORMANCE 2 POLARIS General Information VEHICLE IDENTIFICATION NUMBER referred to in any correspondence regarding warranty service or VIN replacement parts The machine model and V LN number Identification decal 15 located on the right front side of the Tunnel Decal tunnel The V L N 2 number is permanently stamped into the tunnel The model number is embossed on the decal The Tunnel Decal has the Model Number 1 V I N Number 2 and the Manufactured Date 3 These numbers should
72. AD BRACE STEERING POST Never re use lock nuts Always re assemble using new lock nuts T 16 Ft Lbs 22 Nm B 18 Ft Lbs 24 Nm POLARIS 8 5 Steering and Suspensions 2008 IQ Racer Steering Assembly STEERING POST BEARING DRAG LINK RACK PIVOT MOUNT PLATE SPACER NUT 7 LOCTITE gt CENTER IDLER Ts O RING REDUCER BUSHING O RING M BEARING BUSHING 4 IDLER 0 SPACER e Linkage Assembly Measurements IQ Racer Tie Rod Length 16 52in 419 6mm IQ Racer Steering Drag Link Length 4 18in 106mm Never re use lock nuts Always re assemble using new lock nuts NOTE Measurements are rod end center to center with rod ends perpendicular to tie rod A 28 Ft Lbs 38 Nm 11 Ft Lbs 15 Rod end jam nuts C 35 Ft Lbs 47 Nm Apply Loctite 262 to threads D 40 Ft Lbs 54 Nm NOTE Orientate rod ends so they are parallel with mating component 8 6 WIMMING FER FORMANCE POLARIS Steering and Suspensions 2008 600 RR Steering Assembly STEERING POST REDUCER BUSHING _ SPACER P 1 BEARING amp ps 0 Linkage Assembly Measurements 600 RR Tie Rod Length 15 64in 397 2mm CAUTION 600 RR Drag Link Length 6 93in 176mm Never re use lock nuts Always re assemble using new NOTE Measurements are rod end center to center loc
73. CK DISASSEMBLY 9 10 WALKER EVANS REMOTE RESERVOIR PIGGY BACK SHOCK ASSEMBLY 9 11 WINNING PERFORMANCE 9 1 gt POLARIS Shocks SPECIAL TOOLS Shock Rebuilding Tools Special Tools PART NUMBER DESCRIPTION 2200421 Gas Shock Recharging Kit 2201639 Shock 5 Seal Protector 50 Diameter 2201640 Gas Fil Too Ryde FX Shock Special Tools PART NUMBER DESCRIPTION PS 45259 Gas Fill Tool and Gauge Incl 5 needles 549 7 5 45259 2 Gas Fill Gauge replacement 5 45280 Shock Collar Tool PS 45821 Shock Reservoir Holder FOX Shock Special Tools PART NUMBER DESCRIPTION 2871021 Shock Body Holding Tool 2871352 Shock Rod Holding Tool 50 Diameter Rod 2872429 Shock Rod Holding Tool 625 Diameter Rod 2871232 Fox Shock Spanner 2871351 Fox Shock IFP Depth Tool PS 44925 Fox Inner Tube Puller PS 2 POLARIS Shocks SHOCK SHIM PART NUMBERS motion Refer to the appropriate parts manual for a complete listing of shock parts Shock shim stacks can be adjusted to control the amount of fluid that is forced by as the piston travels through its Walker Evans Shock Valve Part Numbers 1800056 1800057 1 200 1800058 1 300 ws 012 025 1800092 1 200 1800093 1 300 1800050 625 065 1800204 875 WIMNING PERFDRMANCE gt POLARIS 1 100 PARTNUMBER 808 55 Weg a0 008
74. G PERFORMANCE C POLARIS Steering and Suspensions REAR SUSPENSION ASSEMBLY ILLUSTRATIONS 2008 Racer RR Pivots and Rear Idler COUPLER BLOCK SHAFT SPACER SHOCK PIVOT SPACER 49 BUSHING REAR PIVOT INNER CARRIER WHEELS STD ON RR NOTE The Racer rear suspension only uses rear idler wheels The addition of inner carrier wheels is optional A 35 Ft Lb 47 Nm Front Track Shock Fasteners 35 Ft Lbs 47 Nm Rear Track Shock Fasteners 25 Ft Lbs 34 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts e All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table POLARIS 8 11 Steering and Suspensions 2008 Racer RR Rail Assembly FRONT REAR SCISSOR STOP SPRING BLOCK RAIL SLIDER NOTE The Racer rear suspension does not use bogie wheels The addition of rail bogie wheels is optional A 3 6FtLb 4 8 Nm B 19 Ft Lb 26 Nm 35 Ft Lb 47 Nm D 35 In Lb 2 Nm E 7 Ft Lbs 9 5 Nm Assembly Notes Never re use Nylock nuts Always replace with new parts e All pivots must rotate freely after tightening fasteners Apply Polaris Premium All Season Grease to all grease zerks as outlined in the periodic maintenance table 12 WINNING PERFORMANCE 8 C POLARIS Steering and Suspensions 2008
75. IS 7 3 Drive and Systems GEARS AND DRIVE CHAINS Drive Chains PART NUMBER DESCRIPTION 3221114 64P 3 4W HYVO CHAIN 3221113 66P 3 4W HYVO CHAIN 3221112 68P 3 4W HYVO CHAIN Drive Gears NOTE CM Cut Metal PM Powder Metal LW Lightweight POLARIS Drive and Systems 7 92 C D CHAINCASE Assembly View BRAKE DISC O RINGS SNAP RING WASHER GEAR DRAIN PLUG SNAP RING BEARING COVER SEAL A 10 Ft Lbs 12 Nm Never re use Cotter pins Always replace with new B 8 Ft Lbs 11 Nm parts C 19 Ft Lbs 26 Nm D 50 Ft Lbs 62 Nm Incorrect chain tension may cause the chain to break E 23 Ft Lbs 31 Nm causing severe chaincase damage Installing gear sets not listed on the Gear Ratio Speed WARNING chart may cause premature gear chain wear Incorrect chain tension may cause the chain to break NOTE Install lower gear washer with beveled side which may result in the loss of braking control out gt POLARIS 7 5 Drive and Systems Chaincase Removal 1 Support the rear of the machine and loosen up the track tension Remove RH side panel Remove the exhaust system Remove the plenum Remove drain plug and drain the chaincase fluid dx Once fluid is drained replace drain plug and torque to specification Drain Plug 10 10 12 Nm 7 Remove driveshaft retaining nuts 8 Remove the Torx screw
76. N 5 10 ENGINE REMOVAL AND 5 5 11 EVO Pi nere 5 11 etas o Chace a a a a 5 12 ENGINE COMPONENT 5 5 5 14 IQ RACER ENGINE MOUNTING 5 14 600 RR ENGINE MOUNTING 5 15 600 IQ RACER ENGINE BULKHEAD 5 16 IQ RACER CYLINDER HEAD COVER CYLINDERS 5 17 IQ RACER PISTON 5 18 IQ RACER RECOIL 5 19 IG RACER GRANICASE 213202 ac yh as 5 20 600 RR IQ RACER WATER OIL 5 21 600 RR CYLINDERS 5 22 600 RR REGOILY MAGNETO 2 2 rior Ded ate bala Owe Pa 5 23 600 RR PISTONS CRANKSHAFT 5 24 600 AR CAANKGCASE m obit doe E 5 25 VARIABLE EXHAUST SYSTEM VES 5 xxr ae eee See ees 5 26 COOLING SYSTEMS oi 5 27 20098 16 600 BB d nats ra eee eS 5 27 2008 IQ 600 RACER ete Ri ee ae HERR
77. N RUN x coco AON lt lt LOCATED IN OIL BOTTLE mi 021 WH YE 020 RD DG 09 GY EDGE BDI CDI HARNESS r E8 DB RD GY DETONATION SENSOR 4 4 870 000 OHMS TORQUE TO 2045 1543 FT LBS THROTTLE ke POSITION 5 POTENTIOMETER SENSOR BK IGNITION COIL aia E28 PK E29 YE E30 BK INE v 6 BK RD 5 24 DB WH 223 WH YE E22 YE RD 031 al 92022 212 312 412 512 612 112812 9130 3 1132 33134 CDI MODULE 015 YE 12131 415 6 7 8 ajia 5611 CONNECTOR 22 YE RD 2324 1211 V 1 YE TO NB 0 15 ToBK RD 15 DG TO GND OPEN DG 15 TO WH RD 185 GROUND RESISTANCE 420 BLACK TO WHITE 3 Q PLUG LEAD TO PLUG LEAD RESISTANCE 20 11 1 PERFORMANCE 109090 WINNING gt POLARIS iagrams D CIVNOI140 X08 18311 8 10 401 031 201 GIONS10S 1415 TWNOLLdO YALYVLS LOCATED ON TOP OF BATTERY BOX OPTIONAL 1 1 I I I I I I I I I I I 12 81 MO113A i HLIM 038 34 08 31dNYX3 40109 32 81 1 NMOHS 580102 3UIM OML ________________________ i MOTTIA 2 HM 3149104 131014 LA 1 1
78. NNEL CIRCUIT HOSE ENGINE OUT TO TUNNEL CIRCUIT THERMOSTAT CONTROLLED TEE FITTING HOSE TO ENGINE LH TUNNEL COOLER FROM FRONT COOLER HOSE TO ENGINE ts FRONT TUNNEL COOLER WATER PUMP COVER SIE RESTRICTOR HOSE BYPASS CIRCUIT ALWAYS ACTIVE 5 27 and Coolinq Systems 2008 IQ 600 Racer CROSSOVER HOSE HOSE TO ENGINE FROM TUNNEL CIRCUIT LIQUID COOLED BRAKE RH TUNNEL COOLER SURGE BOTTLE LH TUNNEL COOLER __ TO ENGINE FROM iru COOLER HOSE ENGINE OUT T0 TUNNEL CIRCUIT ALWAYS ACTIVE CIRCUIT FRONT TUNNEL COOLER HOSE BYPASS CIRCUIT HOSE TO ENGINE ALWAYS ACTIVE CIRCUIT WATER PUMP COVER 5 28 Engine and Cooling Systems Thermostat Replacement BLEED SCREW WASHER HOUSING COVER THERMOSTAT 4 Remove the housing cover by removing the cover bolts Check the gasket condition and replace if damaged gt 3 Replace the thermostat Make sure that spring side is facing downward or toward the engine 4 Replace cover Torque the cover fasteners to specification Cover Fasteners 9 Ft Lbs 12 Nm 5 Verify the bleed screw and washer are installed WINNING PERFORMANCE C POLARIS Thermostat Orientation The thermostat must be installed in the cylinder head has shown in the illustrations Center Thermostat Location BRIDGE ALIGNED WITH HOLES
79. NT ASSEMBLIES IQ Racer Engine Mounting LOCK WASHER A 28 Ft Lbs 38 Nm B 30 Ft Lbs 41 Nm Apply Loctite 242 5 14 PERFORMANCE gt POLARIS Engine and Cooling Systems 600 RR Engine Mounting ENGINE ASSEMBLY 28 Ft Lbs 38 Nm 30 Ft Lbs 41 Nm Apply Loctite 242 5 15 Engine and Cooling Systems 600 RR IQ Racer Engine Bulkhead A B CRANKCASE BRACKET 250 up B A TORQUE LIMITER ASSEMBLY 28 Ft Lbs 38 Nm B 18 Ft Lbs 24 Nm 15 Ft Lbs 20 Nm 5 16 Engine and Cooling Systems IQ Racer Cylinder Head Cover Cylinders HEAD COVER THERMO SENSOR D WASHER CYLINDERS 4 A 70 In Lbs 8 Nm B 9 Ft Lbs 12 Nm Apply Loctite 242 C 25 Ft Lbs 34 Nm Apply Loctite 242 D 18 Ft Lbs 24 Nm Apply Pipe Sealant 42 Ft Lbs 57 Disassembly Assembly Process WINNING PERFORMANCE C POLARIS 10 11 12 13 14 Remove the coolant from the engine using siphon dry vac or drain pan Remove the air box exhaust pipe and resonator from the engine compartment Remove the high tension wires and spark plugs from the cylinder head Remove the thermostat housing outlet cooling hose from the housing Loosen all then remove all head cover fasteners Clean the fastener threads to remove any thread lockin
80. Needle Clip position Q9DGN6 57 3 feet Spring E 0 2000 Throttle Gap Under Cutaway in mm 600 1200 m 2000 4000 1200 1800 si 4000 6000 Black 60 42 36 Recommended Fuel Octane R M 2 eee genated 1800 2400 iis aor i jp een 6000 8000 2400 3000 3000 3600 Drive Clutch Bolt Torque 50 Ib ft 68 1 2 WINNING gt POLARIS Model Specifications General Front Suspension Walker Evans IFP 16 Position Shocks Compression Adjustable Remote Reservoir IFS Spring Rate Spring Installed Length inches Gr 12 00 30 5 Width in cm 48 121 9 Length in cm 110 279 4 Height in cm 44 111 8 Estimated Dry Weight Ib kg 475 215 7 Fuel Gallons Liters 9 34 1 Quarts Liters 2 5124 Cooling System Capacity Quarts Liters TBD Brake Fluid DOT 4 Drive Belt Part Number 3211114 Width inches cm 1 46 3 72 Side Angle 26 Camber Inches cm Not Adjustable Circumference inches cm 45 20 114 8 Toe Out Inches cm 0 1 8 0 0 31 Center Distance inches cm 10 625 27 Ride Out inches mm 10 2 5 Rear Suspension Center Distance inches 7 92 Front Track Shock FTS Walker Evans Top Gear Stock 22 Bottom Gear Stock 39 FTS Shock Oil Volume Chain Stock 74 FTS Nitrogen Pressure 170 psi Gear Lube Polaris Synthetic 80W Walker Evans IFP 16 Position Front Vertical Travel T
81. ORQUE STOP ADJUSTMENT su ia cte peti 3 6 ENGINE d 3 6 SURGE TANI Louie M dua LM RD EM LEM SUL LC LOL EIE 3 6 RECOMMENDED COOLANT a u deh eee nee itd 3 6 COOLING SYSTEM BLEEDING 5 eid iS det hoa 3 6 EXHAUST VALVE CEEANING S ia kak 3 6 OIL PUMP ADJUSTMENT 600RR bei tia 3 7 OIE PUMP BLEEDING rrr 3 7 OLF FUELRICTE Rinia tent 3 7 GHASSISLUBRIGCATION 3 8 FRONT SUSPENSION Au pins 3 8 REAR SUSPENSION kup paspa paha n SS ayam 3 8 THRO TEF CABLE 3 8 42 Saee teer tee p rae Sa 3 8 CHAINCASE Olle positas iet cuties Redes Shee maaa 3 8 CHAINGASE OIL REPLACEMENT 3 9 DRIVE CHAIN TENSION ADJUSTMENT celine Set beatae eke 3 9 BRAKE SYSTEM 3 9 BRAKE EVER TRAVEL 3 9 BRAKE FEUD SEP Ste Me tU 3 9 THROTTLE AND CHOKE CABLE 5 3 10 IDLE SPEED GAP THROTTLE FREE PLAY ADJUSTMENT 3 10 CHOKE LEVER ADJUSTMENT is i aquy dtd tetti 3 10 STEERING SUSPENSION
82. RPM for extended periods of time in any type of snow condition Be patient Warm up engine at least 5 minutes or until it readily responds to throttle input For the quickest most efficient drive away in extreme cold weather take drive belt off machine and bring it in to a warm environment Break skis and track loose from the snow Engage throttle aggressively for short durations for initial cold drive away Cold weather startups When possible do not go in deep snow when towing another machine Use fast effective throttle to engage the clutch Not all machines are intended for pulling heavy loads or other machines Towing another machine at or about engagement RPM Spinning track while vehicle is stuck high RPM low vehicle Lower the gear ratio Remove windage plates from driven speed high ambient temp Example 8000 RPM 10 clutch If possible move to better snow conditions and actual vehicle speed and 60 m p h indicated on speedometer reduce RPM Avoid riding in very high ambient temperatures Break loose snow and ice under tunnel Allow longer than normal warm up Allow belt to warm sufficiently and increase grip ability on clutch sheaves Use fast effective throttle when engaging clutch Ice and snow piled up between track and tunnel overnight or after stopping for a long period of time enough to re freeze the snow Maintain good state of tune including throttle and choke synchronization Check for fouled spark pl
83. Reference the fastener torque specifications at the beginning of the chapter 10 Do not use an impact wrench to install the flywheel nut 5 19 Engine and Cooling Systems IQ Racer Crankcase REED STUFFERS INTAKE BOOTS REED ASSEMBLIES CHECK VALVES NOT USED A 9 Ft Lbs 12 Nm B 22 Ft Lbs 30 Nm Apply Loctite 242 10 Ft Lbs 13 Nm Apply Pipe Sealant NOTE Grease applied to PTO grease zerk at the time of engine manufacture Do not grease fitting unless installing new crankshaft Apply 10 oz to fitting after installing new crankshaft Disassembly Assembly Process I 5 20 Remove the engine from the engine compartment Follow the process for removing the cylinder head cylinders pistons flywheel recoil housing and the water oil pump Remove the intake boots reed stuffers and reed assemblies from the intake tracks Discard any seals or gaskets 10 ALIGNEMNT DOWELS GREASE ZERK Remove the fasteners from the bottom of the crankcase Carefully pry apart the crankcase halves Discard the PTO and MAG crankshaft seals Remove the crankshaft Inspect as required Thoroughly clean the two crankcase mating surfaces with carburetor cleaner and a gasket remover Flush out the crankcase galleries Reinstall the crankshaft back into the lower crankcase using two new crankcase seals Apply a thin bead of Three Bond 1215 to the lower crankcase mating surface Install t
84. SECONDARY LEAD TO PLUG CAPS PERFORHMANMCE gt POLARIS ELECTRICAL SYSTEMS Exhaust Valve Solenoid Resistance Values Coil Resistance WHT YEL to RED 150 15 68 F 20 C Coolant Temperature Sensor Sensor Specifications Knock Sensor 4 810 000 OHMS TORQUE 20 55 15 53 FI LBS PERFORMANCE Ignition Chassis Regulators j Reg IQ Racer Ignition Regulator Rectifier Specifications YELLOW RED Stator Vac Input YELLOW RED CDI 14 5Vdo Output BROWN IQ Racer Chassis Regulator Specifications WIRE COLOR FUNCTION YELLOW 14 3Vac Head Lamp Chassis Circuit a Exhaust Temperature Probe Resistance Values Resistance between both 6 12 68 F 20 C Reading will rise after connecting to multimeter leads 11 3 ELECTRICAL SYSTEMS IGNITION TIMING COMPONENTS Timing Procedure Carbureted Engines NOTE Always verify timing of engine at room temperature 68 F 20 C and at the specified RPM If equipped turn the timing curve selector knob to D 1 Reference the ignition timing chart Install a dial indicator gauge into the MAG spark plug hole 3 Place the MAG piston in the proper timing position then mark the flywheel at this point NOTE Each 10 degree mark is separated by lines every 2 degrees not shown Acceptable timing variance is 2 degrees Fly
85. TTLE VALVE PILOT AIR JET NEEDLE JET VALVE SEAT PILOT JET MAIN JET Mikuni carburetors use a starter enricher system rather than a choke In this type of carburetor fuel and air for starting the engine are metered with entirely independent jets The fuel metered in the starter jet is mixed with air and is broken into tiny particles in the emulsion tube The mixture then flows into the plunger area mixes again with air coming from the air intake port for starting and is delivered to the engine through the fuel discharge nozzle in the optimum air fuel ratio The starter is opened and closed by means of the starter plunger The starter type carburetor is constructed to utilize the negative pressure of the inlet pipe so it is important that the throttle valve is closed when starting the engine Fuel Delivery The pilot system s main function is to meter fuel at idle and low speed driving Though its main function is to supply fuel at low speed it does feed fuel continuously throughout the entire operating range Fuel for the pilot jet is drawn from the float bowl mixed with air jet and delivered to the engine through the pilot outlet FUEL DELIVERY The mixture is regulated to some degree by adjusting the fuel screw 4 5 Fuel Systems The main system is designed to deliver fuel between low speed and high speed operation This system is made up of the jet needle needle jet and main jet The mai
86. UE SPECIFICATION 2 8 FUEL OICPREMIX RATIOS ts 2 8 GASOLINE VOLATILITY naa 2 8 TAP DRILL 2 9 METRIC TAP tena thaqu tains alate 2 9 DECIMAL EQUIVALENT 2 9 MEASUREMENT CONVERSION CHART 2 10 PISTON WASH SPARK PLUG nee 2 10 SERVICE PRECAU TONG x adi cans DER Oboes 2 11 GENERAL PRECAUTIONS 2 11 WINHING PERFORMANCE 2 1 POLARIS General Information RACING NOTES Welcome to the 2007 2008 Polaris Racing season Thank you for selecting the 2008 Polaris 600 IQ Racer snowmobile as your winning vehicle The enclosed technical information which is based on our past experience should be reviewed by your team for machine preparation Do not feel that these suggestions are a must but use them as a starting point The section index enables the user to quickly locate the component unit section desired A table of contents is placed at the beginning of each chapter to aid the user in locating general areas of information Keep this manual available for reference In order to provide you with the best support possible Polaris racing engineering and testing departments must have timely and accurate data fr
87. a 50 13 mm drill motor rotating at a speed of 300 500 RPM run the hone in and out of the cylinder rapidly until cutting tension decreases Remember to keep the hone drive shaft centered to prevent edge loading and always bring the stone approximately 5 1 2 cm beyond the bore at the end of each stroke 4 Release the hone at regular intervals to inspect bore size and finish Cleaning The Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylinder in a solvent then in hot soapy water Pay close attention to areas where the cylinder sleeve meets the aluminum casting transfer port area Use electrical contact cleaner if necessary to clean these areas Rinse thoroughly dry with compressed air and oil the bore immediately with Polaris Premium 2 Cycle Lubricant NOTE Always check piston to cylinder clearance and piston ring installed gap after honing or boring is complete Crankshaft Truing Lubricate the bearings and clamp the crankshaft securely in the holding fixture If truing the crankshaft requires striking with a hammer always be sure to re check previously straightened areas to verify truing Refer to the illustrations below Use Crankshaft alignment kit PN 2870569 NOTE The rod pin position in relation to the dial indicator tells you what action is required to straighten the shaft Truing Examples To correct a situation like thi
88. aa bl ewe bw a ha ES 5 2 ENGINE SPEGIFICATIONS 423 2a mr RR Su he wee we oe Sees bade 5 3 ENGINE SERVICE SPECIFICATIONS ENGINES 5 3 ENGINE INSGPECTIONG ea a 5 4 GYLINDER HEAD INSPECTION 5 4 CYLINDER 5 4 CRANKSHAFT RUNOUT INSPECTION 5 4 PISTON INSPECTION Ec aec wh eae eee eee 9 5 PISTON RING INSTALLED GAP reinu bok Era ax aas Deed decet eec os 5 5 e ER a a 5 5 MAIN BEARIN aide 5 5 CONNECTING ROD LOWER BEARING 5 6 PISTON NEEDLE BEARING ee ERE he hah T 5 6 CRANKSHAET INDEX 5456 rn sod 5 6 CHECKING CRANKSHAFT INDEX 5 7 GY LINDER HONING de tee ua p aspa 5 8 HONING PROGEDURBE 1 14 2x pru ukupak dae IEEE 5 8 CLEANING THE CYLINDER AFTER HONING 5 8 GRANKSHAFF TRUING con dean ek ans Ue ae hh Rone a 5 9 RECOIL ASSENIBEY s 24 2 le og ded eet 5 10 ROPE REMOVAL AND INSTALLATIO
89. always involve compromises A rear suspension set up to perform well in moguls would not suit the preference of a groomed trail rider Weight Transfer The shifting of weight from the skis to the track 15 called weight transfer As engine torque is applied to the drive axle the torque is transferred to the track pulling it forward This energy also tries to pull the suspension forward The front torque arm reacts to this force by pushing down on the front of the track in effect applying more weight to the front of the track and reducing the weight on the skis It is important to note that energy used to lift the front of the machine is not available to push the vehicle forward Changing the angle of the front torque arm changes the suspension s reaction to the force Adjusting the length of the limiter strap will change the front torque arm angle Shortening the strap limits the extension of the front of the suspension reducing the angle of the torque arm and increasing ski pressure during acceleration Lengthening the strap allows the front of the suspension to extend further increasing the angle of the torque arm and decreasing ski pressure during acceleration Limiter strap adjustment has a great affect on weight transfer Limiter straps only affect acceleration It is important to check track tension whenever limiter strap length is changed Front track shock spring preload also affects weight transfer A stiffer spring and or more pre
90. and final spring preload may vary based on rider preference and riding conditions WINNING PERFORMANCE gt POLARIS ROTATE The front rear scissor stop FRSS controls the bump attitude of the rear suspension As the front torque arm FTA hits the bump it forces the rear scissor to collapse a predetermined amount depending on the FRSS block position This accomplishes two important things First it allows a lighter spring rate on the FTA because it can borrow spring rate from the 8 15 Steering and Suspensions rear torsion springs Second it prepares the rear portion of the suspension for the bump reducing secondary kick back The FRSS is made of a resilient material allowing smooth action and preventing any suspension component damage The RRSS controls weight transfer from the rear suspension to the skis It also influences the stiffness of the ride by controlling the amount of coupling action between the front and rear torque arms To decrease weight transfer the RRSS should be set in the high position The RRSS can be removed for maximum weight transfer However unless the torsion springs and rear shock valving are changed the ride will be compromised Always maintain equal adjustment on both sides The dot is an indicator of the HIGH position The sides are the LOW position and the bottom is the MEDIUM position A MEDIUM Limiter Strap Adjustment One method of changing ski to snow pres
91. as LPS2 or WD 40 to ease installation WINNING PERFORMANCE C POLARIS Steering and Suspensions Break In After installing new rail sliders they must be broke in for longer life and better wear patterns When performing the breaking in procedure ride the sled on a surface that has adequate snow conditions with deeper snow nearby Run the sled on the adequate snow surface and dip into the deeper snow every so often REAR SUSPENSION REMOVAL AND INSTALLATION Removal 1 Support the rear of the machine so that the track is off the floor 2 Loosen the rear idler bolts then push the rear idler shaft toward the front of the machine 3 Carefully release the torsion spring pressure if equipped Remove the support from the tunnel letting the suspension carry the weight of the machine 5 Remove the fasteners securing the skid to the tunnel Place a protective mat on the floor and tip the unit over on the left side supporting the sled on the end of the handlebar 7 Collapse the torque arms and remove the suspension from the tunnel Installation CAUTION Always use new fasteners when securing the torque arms to the tunnel 1 With the unit on its left side place the suspension in tunnel 2 Align the front and rear torque arms with the tunnel mounting holes Loosely install two new fasteners NOTE On IQ 121 and Switchback skids verify the rear track shock pivot and brackets are rotated forward
92. ase 12 ft lb 16Nm 3 Place the washers and nuts on to the front and rear motor mounts Rear Torque Stop Plate Torque 28 ft lb 38N m 4 Torque the motor mounts to specification 14 Adjust the torque stop so that it is touching but not forcing on the engine 15 Place the carburetor back onto the intake boots and tighten the hose clamps to secure the carburetors 16 Place the air box into the chassis Connect the electrical items 17 Place the air intake horn onto the airbox and secure it to the Connect the impulse line to the crankcase chassis 18 Replace the drive clutch and torque to specification Replace the hose to the thermostat housing Replace the lower center front cooling hose 10 Connect spark plug leads 11 Replace the front torque arm to the engine plate and route Drive Clutch Torque 50 ft lb 69N m the harness wires in a secure place 5 6 7 Route the recoil rope to the correct position 8 9 19 Place the driven clutch spacers on to the jackshaft 20 Place the driven clutch on to the jackshaft and torque to specification 1 Driven Clutch Torque 12 ft lb 17N m 21 Verify clutch alignment 4 22 Re Install drive 23 Replace belt cover 24 Replace side panels 25 Replace coolant and bleed the cooling system After test running re torque the drive clutch bolt TT 5 13 Engine and Cooling Systems ENGINE COMPONE
93. be 1 nw MADE IN U S A PELARIS PATENT NOTICE by Polaris Industries Inc in Roseau MN under one or NO more of the following patents U S Patents Patented Canada THIS VEHICLE CONFORMS TO ALL APPLICABLE 3 605 511 4 613 310 5 050 559 882 491 71 U S FEDERAL AND STATE REQUIREMENTS AND 3 580 647 3 867 991 5 048 503 83 694 71 CANADA MOTOR VEHICLE SAFETY STANDARDS 3 483 766 4 793 950 5 056 482 864 394 71 IN EFFECT ON THE DATE OF MANUFACTURE 3 533 662 5 03 8 881 5 099 813 3 545 821 5 172 675 5 074 271 34 573 71 3 605 510 5 090 386 5 191 531 34 572 71 MFD DATE 3 525 412 5 050 564 3 613 811 1 FANS VIN Number Designation Vehicle Descriptors Vehicle Identifiers World Mfg ID Individual Serial No gt Engine Size Style Modifier Digit Model Year Mfg Location S EN PUBLICATION PART NUMBERS 2008 Publications MODEL OWNER S MANUAL SUPPLEMENT PARTS BOOK 600 RR 9921514 www polarisindustries com 9921089 www polarisindustries com 2 4 POLARIS General Information ENGINE DATA FORMULAS Compression Ratio 17 o DANGER ZONE UNNECESSARY OCTANE FULL STROKE COMPRESSION RATIO REGULAR PREMIUM RACE FUEL 84 86 88 90 92 100 105 110 115 120 PUMP OCTANE NUMBER R DISP IHV INSTALLED HEAD
94. before attempting to collapse the rear torque arm 3 Setthe machine upright Install the remaining two new torque arm mounting fasteners 5 Torque the rear suspension mounting bolts to specification Align the track guides clips with the suspension rails 7 Adjust the rear idler to achieve the correct amount of track sag 8 17 Steering and Suspensions NOTES 818 s Shocks CHAPTER 9 Shocks 92 SHOCK so cepa eges av aa at ay Bebe nale 9 2 OHOGOCI SIM PART NUMBERS xn 9 3 WALKER EVANS SHOCK VALVE PART 5 9 3 WALKER EVANS SHOCK VALVE PART NUMBERS 71681 9 4 VALVE SHIMARRANGEMENT 32 wie wees ees 9 5 PISTON ORIENTATION ine a eae re ea Nie ee he SQ 9 5 SPECIFICATIONS 5 8 9 6 2008 600RR 600 IQ RACER SHOCK SPECIFICATIONS 9 6 SHOCK VALVE SHIM STACK CONFIGURATIONS 9 7 SHOCK MAINTENANCE acies rer duc She 9 8 SHOCK MAINTENANCE 3 4 0 2 Dux do eet eene d tb Ded albeit eerie 9 8 WALKER EVANS AIR SHOCK DISASSEMBLY 9 9 WALKER EVANS AIR SHOCK ASSEMBLY 9 9 WALKER EVANS REMOTE RESERVOIR PIGGY BACK SHO
95. bulis 7 4 ASIE i ce de aca ee ee 7 5 POOEMBLY VEW 325 eu eod lai ae 7 5 GHAINCASE REMOVAL Sates ate Dii Bert ooh eae ea Z ER PUER E 7 6 GHAINGASE INSTALLATION beet t eet erschossen 7 6 CHAINCASE SEAL BEARING REPLACEMENT 7 7 DRIVESHAFT JACKSHAFT 7 8 ASSEMBLY WEW so stus ea 7 8 JAGKSEIAFTREMOVAL 53 5 Gebers da foie ea 7 9 JACKSHAFT INSTALLATION big eye BAe 7 9 DRIVESHAFT REMOVAL INSTALLATION 7 9 BRAKE Of OVE EV ee da Ve EAE PIS 7 10 bos 7 10 COMPENSATING PORT snc pos APIS me 7 10 GENERAL GUIDELINES tel eene 7 11 BRAKE FLUID REPLACEMENT BLEEDING 7 11 MASTER CYLINDER LEVER SERVICE 5 atone y 12 BRAKE HOSE REPLACEMENT 5 arb de Re hart 7 13 CALIPER REPLACEMENT 2 2 oa as 7 13 GALIPER ASSEMBLY a Se 7 13 BRAKE REPLACEMENT zas oe 2OH rule y 7 13 BRAKE DISC REPLACEMENT
96. ck nuts loosely 5 Insert the track 6 Insert the driveshaft and careful guide it through the lower bearing of the chain case 7 Loosely install the lower sprocket on the drive shaft with the retaining bolt This will keep the driveshaft from falling through the other side 8 Install the rear suspension 9 Tip machine over so that it is upright 10 Support the rear of the machine with a jack stand 11 Center the track so that it is contacting the drive shaft drivers correctly 12 Remove the jackshaft installation tool from he jackshaft 13 Install the jackshaft alignment tool on jackshaft and torque enough so that the jackshaft is aligned with the chaincase bearing 14 Torque all chaincase retaining bolts to specification Chaincase Bolts 28 ft lb 38 Nm 15 Remove the jackshaft alignment tool from jackshaft 16 Install brake caliper and torque the retaining bolts to specification Brake Caliper Bolts 19 21 26 28 Nm 17 Install the driveshaft by replacing the flange nuts on the drive side Torque to specification Driveshaft Flange Nuts 17 23 Nm 18 Torque the jackshaft flange nuts to specification Jackshaft Flange Nuts 17ft Ib 23 Nm 19 Remove the loosely placed lower gear and retaining bolt 20 Place the upper sprocket lower sprocket into the chain and install it onto the shafts in the chaincase PERFORMANCE gt POLARIS Dr
97. cted Belt Width 1 Measure the belt width and replace it if it is worn severely Generally a belt should be replaced if the clutches can no longer be adjusted to provide the proper belt deflection Project the side profiles and measure from corner to corner Place a straight edge on each side of the drive belt and measure the distance where the straight edges intersect at the top A B 2 Inspect the belt for loose cords missing cogs cracks abrasions thin spots or excessive wear spots Replace if necessary 3 Inspect the belt for hour glassing extreme circular wear in at least one spot an on both sides of the belt Hour glassing 6 10 Circumference 46 625 118 4 46 62 118 4 45 79 116 45 79 116 46 77 118 8 45 2 114 46 77 118 8 Outer in cm MBL High Performance Race Belt Sanded Finish MBL High Performance Belt Sanded Finish occurs when the drive train does not move and the drive clutch engages the belt Example would be taking off while the track is frozen to the ground Remember to always warm up the track and free it from the ground WIHNING gt POLARIS System Belt Wear Burn Diagnostics Table 6 1 Belt Wear Burn Diagnostics POSSIBLE CAUSE SOLUTION Drive at higher RPM if possible Gear the machine down Make sure belt deflection is at 1 1 4 to achieve optimum starting ratio Driving at or about engagement
98. d and resting at normal ride height not full rebound Measure at a point 10 2 54cm forward of the ski 8 2 mount bolt and 10 2 54cm behind the ski mount bolt preferably on the center line of the carbide skags Camber amp Toe Specifications MAXIMUM SET UP WIDTH in CAMBER in cm mm s 25 At ride height in mm NOT ADJUSTABLE Springs When the front suspension encounters a bump the force of the bump compresses the spring If the bump force is 450 pounds a 100 in spring will compress 4 5 inches A 150 in spring will compress 3 inches If the suspension had 4 inches of spring travel the 100 in spring would bottom out while the 150 in spring would have one inch of travel remaining Free length the length of a coil spring with no load applied to the spring Installed length the length of the spring between the spring retainers If the installed length of the spring is less than the free length it will be pre loaded Spring rate the amount of force required to compress a coil spring one inch For example if 150 pounds of force are required to compress a spring inch the spring rate would be 150 in Straight rate spring the spring requires the same amount of force to compress the last one inch of travel as the first one inch of travel For example if a 150 in spring requires 150 pounds of force to compress it one inch 300 pounds o
99. e FRSS IQ 121 IQ 136 Coupled IQ Comfort and not collapsed rearward when installing the rear skid assembly REAR TRACK SHOCK PIVOT WINNING PEA FORAWMAANCE gt POLARIS Ski Assembly BUMPER TOE LOOP CAUTION Never re use lock nuts Always re assemble using new lock nuts A 36 Ft Lbs 49 Nm B 5 7 Ft Lbs 7 9 Nm 8 10 Ft Lbs 11 13 Nm Assembly Notes Install spindle bumper with flat side facing forward e Replace wear bar carbide when damaged or when carbide edge is worn away 8 3 Steering and Suspensions FRONT SUSPENSION ASSEMBLY ILLUSTRATIONS 2008 IQ Racer 600 RR Front Suspension e ASSEMBLY SPHERICAL BEARING C jos RING UPPER SPINDLE LOWER SPINDLE Sy BUSHING NOTE Assembly Notes Note washer installed between fastener and pivot A CAUTION bushing on the rear lower control arm mount to allow sufficient clearance between nut and sway bar Never re use lock nuts Always re assemble using new lock nuts Orientate rod ends so they are parallel with mating component 29 Ft Lb 39 Nm Shock Mounting Fastener Nuts 28 Ft Lbs 38 Nm Tie Rod End Nylock Nuts 35 Ft Lb 47 Nm D 60 Ft Lb 81 Nm 8 4 WINNING C POLARIS Steering and Suspensions IQ Racer 600 RR Steering Post BRACKET SPACER STEERING HOOP BULHE
100. e force will be exerted on the moveable sheave C POLARIS 6 3 PVT System GENERAL INFORMATION Special Tools Team 12 Cooling Fin Driven Clutch Offset Alignment Tool Team 24 Cooling Fin Driven Clutch Offset Alignment Tool gt POLARIS PVT System Drive Clutch Springs WIRE PART NUMBER COLOR DIAMETER inches LOAD FREE LENGTH FORCE LBS 2 50 RATE 125 119 12 LBS ins sinch 7041021 7041063 Purple 75 13 9e oam mem xw 9 m NOTE Springs listed as color will have the spring coil Tag each spring with the part number last four digits of the part number painted on the spring force when not in use gt POLARIS 6 PVT System Spring Free Length 10 Series Weights Measure the drive and driven spring free length with the spring WEIGHT GRAMS 1g PART NUMBER resting on a flat surface Replace spring if out of specification OR 1321590 MW 1321527 321529 10A L M 1321531 30k 18H89 1054 1321635 10 56 1321684 ose 58 1921588 0 80 1321587 TAE 10 62 62 1321586 In addition to proper free length the spring coils should be 16 parallel to one another when placed on a flat surface Distortion 10 62M 1321614 of the spring indicates stress fatigue Replacement is
101. e puller center bolt in until the flywheel pops off of the crankshaft 5 23 Engine and Cooling Systems 600 RR Pistons Crankshatft PISTON RINGS PISTON NEEDLE BEARINGS 9 MAG CRANKCASE SEAL Disassembly Assembly Process I 2 To remove the pistons follow the process for removing the cylinder head and cylinders from the engine To remove the crankshaft follow the process for disassembling the crankcase assembly With the piston out of the cylinder remove one of the c clips and discard Never re use piston c clips Push the piston pin out of the piston and upper rod bearings Inspect the pin for galling and abnormal wear Inspect the needle bearing by feel and replace as required New pistons are supplied with new rings and a piston pin It is recommended that new needle bearings be installed as well When installing a new piston insert one c clip into the piston making sure the open end is 180 opposite of the groove opening Apply a liberal amount of Polaris two stroke engine oil to the needle bearings piston pin and piston assembly Push the pin in to the piston then through the needle bearing Install the remaining c clip with the open end is 180 opposite of the groove opening NOTE Always use new cylinder base gaskets 9 24 10 Apply a liberal amount of Polaris two stroke oil to the cylinder wall Align the piston ring gaps around the piston locating pins Compress
102. ect a Mity Vac to impulse fitting or line and apply 4 6 PSI pressure Diaphragm Fuel Pump Overview should hold pressure indefinitely FUEL IN FROM TANK IMPULSE HOSE FITTING T ALWAYS ON BACK OF PUMP The impulse powered fuel pump on carbureted engines works by using the positive and negative pressure pulses generated by the movement of the pistons inside the engine crankcase When the MAG piston is on the upward stroke negative vacuum pressure pulse is applied to the fuel pump This action draws fuel into the pump from the fuel tank When the MAG piston is on the downward stroke a positive pressure pulse is applied to the fuel pump This action forces fuel from the intake side of the pump to the supply side then to the carburetors A series of check valves prevents fuel from being drawn out of the carburetors on the vacuum stroke or forced back into the fuel tank during the pressure stroke Maintenance The impulse operated powered fuel pump does not require any specific scheduled maintenance However the following procedures should be observed Operation The pump may be checked for operation by removing the fuel supply line from the carburetor and placing it into a container With the engine idling at approximately 2000 RPM a steady flow of fuel should be visible Cleaning The impulse line must be disassembled and cleaned of foreign material in the event of piston or other internal engine part
103. eding 7 11 Compensating Port 7 10 Fluid Change 7 11 Overview 7 10 Carburetor Synchronization 4 12 Chaincase Chains 7 4 Gears 7 4 Chaincase Installation 7 6 Chaincase Oil Replacement 3 9 Chaincase Removal Chassis Assembly Bulkhead and Tunnel 10 2 Console 10 4 Footrest Structure 10 3 Hood 10 5 Hood Mounting 10 6 Nosepan and Side Panels 10 7 Seat 10 4 Choke Lever Adjustment Coolant Surge Tank Level 3 6 Cooling System IQ 600 Racer 5 28 IQ 600 RR 5 27 Thermostat Orientation 5 29 Cooling System Air Bleeding 3 6 Cooling System Bleeding 3 6 Crankcase Inspection Bearing fit 5 5 Crankshaft Runout Inspection 5 4 Truing 5 8 Crankshaft Indexing 5 6 Crankshaft Inspection Checking Crankshaft Indexing 5 7 Connecting Rod small end 5 6 Connecting rod bearing 5 6 Indexing 5 6 Main bearing 5 5 Crankshaft Truing 5 8 Cylinder Honing 5 7 Cylinder Measurements 5 4 D Detonation Control DET 11 9 Drive Belt Deflection Adjustment 222 Drive Deflection Inspection 3 5 Drive Chain Tension Adjustment 3 9 Drive Clutch Assembly 6 17 Disassembly 6 15 Identification 6 14 Removal 6 14 Rol
104. ehes m 11 5 29 1 Suspension Setup Width Not Adjustable Inches cm Capacity oz ml 9 266 2 Rear Track Shock RTS Compression Adjustable Remote Reservoir Electrical Torsion Spring Diameter 347 Square Tail Angle Rear Travel Inches 13 9 35 3 Reverse System Perc Alternator Output Operating Voltage 13 5 14 5 Watts 13 5 Vdc Total 280 Ignition Timin 5 5 TPS Un plugged Spark Plug Gap in mm 027 70 Spark Plug Champion RN57YCC Track Width Inches cm 15 38 Length Inches cm 121 307 Lug Height Inches cm 1 25 3 175 Track tension sag in cm with 10 165 4 54 placed 16 in 40cm ahead of rear idler shaft 1 1 4 1 1 2 3 2 3 8cm WINNING PER FORMANCE 1 POLARIS 3 Model Specifications 2008 600 IQ Racer Carburetor Jetting Model Number S08MX6JS SOBMX6JE Engine Altitude Meters feet Liberty Liquid Cooled Case Reed Induction Model Number 53577 6044 PU6J Engine Type lt 25 F lt 35 C gt 60 F gt 16 C 15 F to 5 F 26 C to 15 C O F to 20 F 18 C to 7 C O gt as gt 0 600 20 500 490 480 460 450 430 420 0 2000 2 5 30 F to 10 F 34 C to 23 C 15 F to 35 F 9 C to 2 C 30 F to 50 F 1 C to 10 C Displacement Cylinders 599cc 2 Bore inches m
105. em If a fuel line has been damaged or kinked it must be replaced All models feature a fuel pick with filter located inside the fuel tank To inspect and replace 1 Remove the gas cap Use a coat hanger to carefully pickup the fuel hose inside the tank 3 Inspect and replace the pickup filter at the end of the hose 3 7 Maintenance CHASSIS LUBRICATION Most chassis suspension and mechanical grease points should be lubricated Polaris Premium All Season Grease Polaris Premium All Season Grease Part Numbers 30z Grease Gun Kit 2871312 140z Tube 2871423 Front Suspension Lubricate grease zerks with Premium All Season Grease Rear Suspension Lubricate grease zerks with Premium All Season Grease 3 8 Throttle Cable Lubricate the throttle cable lightly with fresh oil With the engine off turn the handlebars to the left and lubricate well as shown Choke And Choke Cable Lubricate the choke slide and cables lightly with oil or grease Before turning the engine off operate the choke intermittently to draw moisture out of the choke plunger area and reduce the possibility of the choke becoming frozen Chaincase Oil Maintain the oil level between the safe marks on the dipstick whenever checking or changing oil Position the vehicle on a level surface Remove the dipstick 1 Verify level is in SAFE zone Add the recommended oil as needed Do not overfill Clean the
106. ement amp Bleeding on page 7 11 PERFORMANCE gt POLARIS Drive and Systems Brake Hose Replacement 1 Attach the other end to a Mity Vac or similar vacuum tool Remove all of the brake fluid 3 Note the ortentation of the brake hose The brake hose will need to be replaced in the same orientation 4 Remove the brake hose from the caliper Cap or cover the end to catch any brake fluid that may still be in the hose 5 Remove the brake hose from the master cylinder Install new brake hose on caliper and orientate it as noted in step 3 7 Torque brake hoe fitting to specification Brake Hose Caliper Fitting 240 264 In Lbs 27 29 8 Install the new brake hose into the master cylinder using new copper crush washers Torque the brake hose to specification Brake Hose Banjo Bolt 240 264 In Lbs 27 29 Nm 9 Follow the bleeding procedure See Brake Fluid Replacement amp Bleeding on page 7 11 Caliper Replacement The only serviceable items in the brake caliper is the brake pads piston and seals If any service is required of the caliper a new caliper is available BRAKE PISTON SEAL Oss SEAL BLEED SCREW gt POLARIS 1 Note the orientation of the brake hose before removing it Remove the banjo bolt from the brake hose and tie up so that all the brake fluid does not
107. engine is at operating 010 030 25 80mm temperature 2 Reference the Throttle Gap Under Cutaway specification 5 Secure the adjuster jam nuts THROTTLE CABLE Choke Lever Adjustment r 1 the choke toggle to the OFF position 1 8 1 4 3 6 cm Freeplay THROTTLE SLIDE Throttle Gap Under Cutaway 2008 600 RR Gap 2 5mm 2008 IQ 600 Racer Gap 2 0mm 3 Turn idle speed adjustment screw the carburetor rack clockwise or counter clockwise until the gap under the throttle slide is set to specification 3 10 db ovas Maintenance 2 Loosen choke cable lock nuts STEERING SUSPENSION MAINTENANCE THROTTLE CABLE CHOKE CABLE Handlebars Periodically inspect the torque of the handlebar clamp fasteners JAM NUTS 3 Adjust the lock nuts on the carburetor until choke toggle has zero free play then set the lock nuts so there is 1 8 to 1 4 3 6 toggle free play NOTE Verify the plungers do not lift when checking the free play 15 17 Ft Lbs 20 23 Nm 4 Tighten adjustment lock nuts WINNING PERFORMANCE 11 C POLARIS Maintenance Ski Ski Skag Fasteners Periodically inspect the ski to spindle fasteners for proper torque BUMPER TOE LOOP WEAR BAR CARBIDE CAUTION Never re use lock nuts Always re assemble using new lock nuts A 36 Ft Lbs 49 Nm 5 7 Ft Lbs 7 9 Nm 8 10 Ft Lbs 11 1
108. es only needed if system was completely drained of fluid properly after any brake system work has been per Bleed each line connection starting with the fitting formed or when inspection reveals spongy brakes closest to the master cylinder working toward the caliper and ending with the bleed screw A soft spongy feeling in the brake lever and or brake pedal could indicate a hazardous condition in the brake system Do not operate the vehicle until the failure in the brake system is corrected Always torque banjo bolts and other brake system fittings to specified torque Change fluid every 2 years or when fluid is dark or ous contamination is suspected Keep brake fluid tightly sealed and out of reach of chil orem Brake fluid can accumulate moisture reducing Brake Fluid Replacement amp Bleeding it s effectiveness This procedure should be used to change fluid or bleed brakes Contaminated brake discs or brake pads greatly re during regular maintenance or after complete brake service duce braking performance and increase stopping dis Brake fluid may damage painted or plastic surfaces Take care tance Do not attempt to clean contaminated pads not to spill and wipe up any spills immediately Cover parts to Replace them Clean the brake disc with brake cleaner avoid damage This brake system requires ethylene glycol based fluid 1 Clean the reservoir cover DOT 4 Do not use or mix different types of fluid such as s
109. etailed Specifications 5 3 Fastener Torque Guide 5 2 IX 1 IX Service Specifications 5 3 Engine Torque Stop Adjustment 3 6 Exhaust Segoe M REA 4 14 Exhaust Valve Cleaning 3 6 F Filters Oil and Fuel 3 7 Front Suspension Alignment Bar Specifications 8 9 Assembly Illustration 8 4 Setup and Adjustments 8 9 Handlebar Centering 8 10 Rod End Engagement 8 9 Rod Ends 8 9 Toe Adjustment 8 10 Front Torque Arm Limiter Strap Adjustments 8 16 FUCK INCE or cuc E cuy Ro 3 7 Fuel Pump Maintenance 4 0 Fuel Pump Overview 4 9 Fuel Systems Service Warnings and Precautions 4 2 G a phatu p 7 2 General Information Racing Department Contacts 2 2 Racing Notes 2 1 General Reference 2 8 Decimal Equivalents 2 9 Fuel Oil Premix Ratios 2 8 Gasoline Volatility 2 8 Measurement Conversion Chart 2 10 Metric Tap Drill Sizes 2 9 SAE Tap Drill Sizes 2 9 Service Precautions 2 11 Standard Bolt Torque Specification 2 8 Handlebar Assembly 8 8 Handlebar Torque Adjustment 3 11 Honing Procedure 5 8 Cleaning the cylinder after honing 5 8 Idle Speed Gap Throttle Lever Free Play Adjustment 3 10 PS x ioo piso do pied oed NL OR bte ae 8 2 TEM see os
110. f force would compress it two inches 450 pounds of force would compress it three inches etc Progressively wound spring the rate of the spring increases as it is compressed For example a 100 200 in rate spring requires 100 pounds of force to compress the first one inch but requires 200 additional pounds to compress the last one inch WINNING PERFORMANCE C POLARIS Steering and Suspensions Suspension Mounting Fastener Torque Torque Specification 45 55 Ft Lbs Torque Arm to Tunnel Fasteners 61 75 Nm Front Suspension Shock Fasteners Front Track Shock Fasteners 29 Ft Lbs 39 Nm 35 Ft Lbs 47 Nm 25 Ft Lbs 34 Nm Hear Track Shock Fasteners CAUTION Torque arm fasteners are pre coated with thread locking agent Always replace with new fasteners Never re use Nylock nuts Always replace components with new nuts Rear Track Shock Pivot Orientation The rear track shock pivot must be properly located on all IQ rear suspensions when installing the rear skid into the tunnel Failure to properly locate the rear track shock pivot may cause the rear torque arm to lock IQ rear track shock pivots with the exception of IQ RMK and race suspensions must be located as shown below On IQ and race rear suspensions the shock pivot is orientated upwards Always verify the rear torque arm scissor is pushed forward so that it is either straight up IQ IQ Shift or against th
111. failures which produce fragments nspection POLARIS Fuel Systems CARBURETOR SERVICE NOTE Keep track of the plastic washer 9 and place it so it is on the top of the throttle valve when installing the needle and e ring back into the Disassembly carburetor T cli 1 CAUTION 4 the needle 7 8 and plastic washer 9 for WEAR EYE PROTECTION WHEN USING COMPRESSED AIR OR WHEN USING CLEANING SOLVENTS REVIEW ALL FUEL SYSTEM WARNINGS LOCATED AT THE BEGINNING OF THIS CHAPTER BEFORE PROCEEDING 1 Remove the carburetor from the engine before disassembling Clean the outside of the carburetor thoroughly with solvent Do not use compressed air to dry at this time 2 Remove all top cap screws 1 top cap 2 and gasket 3 5 Remove the four screws 10 on the funnel face 6 Turn throttle shaft so the throttle slide 11 slides open all the way 7 With slide fully open pull funnel 12 out from the bottom first Inspect the gasket 13 8 Check for wear on the faces of the slides 3 Locate the arm screw 4 and loosen it just enough to move the arm 5 out of the way so that you can remove the needle 6 e clip and the plastic washer from the throttle slide 4 10 POLARIS Fuel Systems 9 Inspect e rings plate spring and rings 14 connecting the 14 Remove and inspect the main jet 20 pilot jet 21 and slide to the lever if needed starter jet 22 C
112. ft of the stationary sheave CLUTCH SPACER 6 Thread the spider onto the stationary sheave shaft 7 Index the spider See Spider Indexing on page 6 18 8 Using the spider tool PN 2870341 torque to 200 ft Ib 276 9 Install the jam nut 6 onto the shaft and torque it to 235 ft Ib 324 Nm 10 Place the drive spring on the shaft 11 Place the cover onto the clutch and torque the cover fasteners to 90 in Ib 10Nm NOTE Do not allow side loading or mis alignment of the cover or the bushing may become damaged Pons 6 17 PVT System Spider Indexing NOTE Spider indexing effects belt to sheave clearance and clutch balance Please read all procedures before proceeding 1 Remove and disassemble clutch Add or remove spider washers as required to achieve desired belt to sheave clearance Make sure that the stepped washer A is on the bottom of the spacer stack B For example If belt to sheave clearance is 020 too large removing one 020 shim will position the movable sheave closer to the fixed sheave reducing belt to sheave clearance by 020 3 Place the correct number of spacer washers B beneath the spider The following washers are available for fine tuning 5210752 020 51mm 5242981 025 63mm 5210753 032 81mm 5210754 050 1 27mm Clutch Spacer 130 3 3mm 4 Install spider washer s and spider aligning the X with
113. g links the movement of the front and rear torque arms to each other 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 The factory setting are usually adequate for all riders in all conditions 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 arm and the front torque arm Adjusting the RRSS to a lower setting allows more weight to transfer to the rear for more traction Adjusting the RRSS to a higher position will reduce weight transfer improve chatter bump ride and improve cornering performance WINNING PERFORMANCE C POLARIS Steering and Suspensions REAR SUSPENSION ADJUSTMENTS Adjustment Procedures NOTE Break in the suspension for at least 150 miles 240 km before making adjustments All settings will vary from rider to rider and are dependant on rider weight vehicle speed riding style and trail conditions Always start with the factory settings Make individual adjustmen
114. g residue Discard the head cover and cylinder head o rings Always use new o rings during assembly Inspect the cylinder head combustion domes for any damage Measure cylinder head flatness Replace cylinder head if required Loosen all then remove the cylinder bolts Clean the bolt threads to remove any thread locking residue Carefully pull each cylinder upwards taking care not to drop the piston and rod abruptly against the crankcase Remove the cylinder base gaskets Use a gasket scraper to clean the gasket residue from the crankcase and cylinder bases Inspect the cylinder walls Nicasil cylinders can only be lightly honed Damage that cannot be removed with a light hone requires cylinder replacement or re chroming The assembly process is the reverse of disassembly Always use new gaskets and o rings during assembly Liberally coat the inside of each cylinder and the outside of each piston with Polaris two stroke engine oil When installing a piston into a cylinder verify each piston ring opening is located at each piston ring locating pin Squeeze the top ring then carefully slide the cylinder over the compressed ring Do the same with the bottom ring Follow the torque specifications and torque sequences located at beginning of chapter when tightening fasteners 5 17 and Cooling Systems IQ Racer Piston Crankshaft PISTON PISTON 2 FLYWHEEL KEY Disassembly Assembly P
115. ger connected to the backside of the pulley NOTE If all of the recoil spring tension was removed the spring should stay inside the housing when the pulley is removed 4 6 5 10 Inspect all components for signs of abnormal wear and tear Replace components as required If replacing the rope tie a small square knot at one end Push the knot firmly into the pocket on the pulley If the pulley recoil spring was removed during disassembly install the spring by spiraling the spring counterclockwise toward the center of the housing Lubricate the center shaft and spring with Premium grease 10 11 12 13 14 19 16 L7 18 Wind the rope counterclockwise around the pulley as viewed from the ratchet side of the pulley Pass the end of the rope through the hole in the housing If the rope guide was removed from the housing reinstall it before attaching the rope handle Slide the pulley down the center shaft and into the housing making sure the recoil spring re engages the pulley tab Install the ratchet spring and ratchet into the pulley face The ratchet spring leg fits in the notch on the ratchet and holds the ratchet in retracted Install friction spring with one leg inserted in the bottom hole on the ratchet Install nut and torque to 5 ft lbs 7 Nm Pull rope out to its full extension and align pulley notch with rope hole in housing Using a needle nose pliers or hooked wire pull a loop
116. h may cause clutch taper to corrode or damage the crank seal 4 Clean clutch taper with lacquer thinner or isopropyl alcohol 5 Slide clutch onto crankshaft taper Install the retaining bolt with all spacers and washers or rings that were on the bolt when it was removed 7 Hold the clutch with the holding wrench PN 931417 A 8 Torque bolt to specification 9 Run engine then re torque the retaining bolt to specification DRIVEN CLUTCH Driven Clutch Removal 1 Remove the drive belt 2 Apply and lock the parking brake 3 Remove the driven clutch bolt and washers A NOTE Count the number and location of the spacer washers located on the fastener and behind the clutch 4 Slide the driven clutch off the jackshaft 5 Inspect splines and replace Jackshaft if damage is found gt POLARIS Driven Clutch Installation 1 Install the driven clutch bolt with the same amount of washers at removal 2 Torque the bolt to specification 3 Check for correct belt deflection 6 19 PVT System Team LWT Components SCREWS DEFLECTION SPACER STATIONARY SHEEVE MOVEABLE SHEEVE BELT DEFLECTION SCREW 10 Install and torque helix fasteners to 60 80 in Ibs 7 9 Nm Helix Fasteners 60 80 In Lbs 7 9 Nm Driven Clutch Retaining Fastener 17 Ft Lbs 23 Nm Disassembly and Assembly Process 1 Remove the scre
117. he jet needle Siraig ht Portion This needle example is a 9DH01 57 The first number is the approximate overall length in 10mm increments of the jet needle The 9 indicates the needle is approximately 90mm but less that 100mm in length The letters on the jet needle indicate the angle of both tapers The first letter designates the taper angle of the top section closest to the grooves and the second letter designates the angle of the bottom taper The taper angles are graduated in 15 15 minute increments The jet needle marked 9DH01 57 would have a top taper of 1 0 and a bottom taper of 2 0 The number following the letters on the jet needle 1s the serial number and it varies with individual jet needles _ Paper te bottom section ofthe needle 57 Outside diameter O D of the straight portion Needle Jet The needle jet works in conjunction with the jet needle Throttle Opening Vs Fuel Flow gt POLARIS Fuel Systems Large Clearance VM only Closed One half Full Throttle Throttle Throttle 5 1005 Throttle Opening INCREASING Ja 14 38 1 2 5 8 3 4 FULL THROTTLE OPENING TYPICAL MIKUNI VM e Throttle Cut Away ue Jet Needle Needle Jet DECREASING gt ___ ite POLARIS Fuel Systems FUEL PUMP Disconnect impulse line from pump Conn
118. he upper crankcase Loosely install the crankcase fasteners then torque to the specifications at the beginning of the chapter Use the correct torque sequence when tightening the screws Liberally coat the crankshaft bearings and components with Polaris two stroke engine oil WI HH lI C POLARIS PERFOR Engine and Cooling Systems 600 RR IQ Racer Water Oil Pump WASHER MECHANICAL SEAL WASHER NUT OIL PUMP IQ RACER OIL PUMP COVER NOTE The IQ Racer does not feature oil injection A cover plate is screwed into the crankcase in place of the oil pump The IQ Racer engine uses a flange nut in place of a washer and nut to secure the impeller to the cross shaft A 7 Ft Lbs 9 5 Nm B 10 Ft Lbs 13 Nm C 9 Ft Lbs 12 Nm Disassembly Assembly Process 1 Remove the coolant from the engine using a siphon wet dry vac or a drain pan 2 Remove the airbox exhaust pipe and resonator Remove the hose connected to the water pump cover 3 To access the impeller and mechanical seal remove the water pump cover Discard the water pump cover gasket 4 Remove the impeller nut impeller and washers from the PERFORMANCE gt POLARIS 10 11 WATER PUMP COVER GASKET cross shaft Carefully pry the mechanical seal and seal out of the crankcase Water pump assembly is the reverse of disassembly Always use new seals and gaskets during assembly To rem
119. her adjustments 8 Loosen up the rear idler shaft 9 After any adjustments are complete be sure to torque the locknuts E to 35 ft Ib 48 N m Adjuster Lock Nuts 35 ft Ib 48 N m WINNING PERFORMANCE gt POLARIS 10 Torque both idler shaft bolts F to 35 ft lb 48 N m 35 1 6 48 Idler Shaft Bolt 35 ft lb 48 N m Broken track rods can cause a rotating track to come off the machine Never operate or rotate a damaged track under power with a broken rod Serious injury or death may occur Stay clear of all moving parts to avoid personal injury Never make any adjustments with the engine running as serious personal injury can result 3 13 Maintenance ELECTRICAL SYSTEMS Headlight Bulb Replacement NOTE Do not touch the bulb with your fingers The grease from body oil will cause a hot spot on the bulb and cause bulb failure If you do touch the bulb clean the bulb with isopropyl alcohol Push in on PUSH section of the plenum Slide the access panel down to gain access to the bulb Squeeze and move the bulb clip up Replace the bulb clip and access panel OFF SEASON STORAGE Chassis And Hood Proper storage starts by cleaning washing and waxing the hood chassis upholstery and plastic parts Clean and touch up with paint any rusted or bare metal surfaces Ensure that all corrosive salt and acids are removed from surfaces before beginning preservation
120. ie ates matices adiu usu has bars e tas 6 6 PERC TEAM LWT DRIVEN HELIXES 24 6 7 NON PERC TEAM LWT DRIVEN HELIXES 24 FIN 6 7 PERC TEAM DRIVEN HELIXES 12 6 7 NON PERC TEAM DRIVEN HELIXES 12 6 8 TEAM RAMP ANGEES 2 Sue RE Sus ha 6 8 TEAM DRIVEN SPRINGS rL u ad Lp de Fg ptc Roe eee e 6 9 DRIVE BELTS a encre teh Part dud epe uer ee Be 6 10 BELT INSPECTION 2 iade once EAE sss 2 RAIL ap Os edd 6 10 BELT WEAR BURN DIAGNOSTICS 6 11 DRIVE BELT REMOVAL TEAM DRIVEN 6 12 DRIVE BELT INSTALLATION TEAM DRIVEN 6 12 ADJUSTING BELT DEFLECTION TEAM DRIVEN CLUTCH 6 12 PVIESYSTEM ADJUSTMEN TS 4 12 xoa ret Yo be 6 13 GLOTGH ALIGNMENT OFFSET 6 13 OFFSET ADJUSTMENT scot tec hupu apash dos Y ok err eee eee eee ees 6 13 peu m aac ases a 6 14 IDENFIEICATION 6 14 DRIVE CLUTCH REMOVAL 42 eoo CONS eer eee ae 6 14 DRIVE CLUTCH DISASSEMBLY
121. ifications Carbureted Engines 14 00 0 1 Vdc WOT 7 verify the TPS is sending a linear signal slowly move the throttle flipper from the closed to WOT position then back down to the closed position 8 The voltage readings displayed on the multimeter should rise and fall without erratically jumping from high to low NOTE The multimeter display may change scales and show O L momentarily when throttle flipper is moving 9 Ifthe signal readings are erratic replace the TPS sensor gt POLARIS TPS Adjustment Carbureted Models NOTE Always verify the engine idle speed is set at engine operating temperature and the throttle cable freeplay is set to 0 10 0 30 1 Connect the TPS test tool to the TPS Slightly loosen the screws securing the TPS to carburetor body 3 Have an assistant hold the throttle flipper in the WOT position 4 Turn the TPS clockwise to decrease voltage or counterclockwise to increase voltage 5 Carefully tighten the TPS screws when the WOT Vdc is 4 00Vdc 11 7 ELECTRICAL SYSTEMS SWITCHES Tether Switch Brake Li g ht Switch Removed Handwarmer Thumbwarmer Switch Yellow Blue X Handwarmer OR GRY X Thumbwarmer BLU RED Handwarmer W PUR Thumbwarmer Dragon Fire Switch e PELARIS ELECTRICAL SYSTEMS 2008 600 RR Regulator Rectifier The regulator rectifier on a 2008 600 RR l
122. ifications 2008 600 IQ Racer 1 4 2008 600 RR 1 2 O Off Season Storage Procedures 3 14 ONFE ash da bers ASE Tee Eee 3 7 Oil Pump Bleeding 3 7 Oil Pump Adjustment 600 RR 3 7 Overview 2008 600 IQ Racer 2 2 2008 600 RR 2 2 P Periodic Maintenance Table 3 2 Piston Inspection 5 5 Piston Ring Installed Gap 5 5 Piston Wash Reading 2 10 PVT System Adjusting Belt Deflection 6 12 Drive Belts 6 10 Drive Clutch Springs 6 5 Non ER LW Driven Helixes 6 7 6 8 Special Tools 6 4 Team Driven Springs 6 9 PVT System Overview 6 2 Fall 8 16 Rear Suspension Adjustment Procedure 8 15 Rear Suspension Assemblies Front and Rear Torque Arms 8 13 Pivots and Rear Idler 8 11 Rail Assembly 8 12 Rear Suspension Coupling 8 14 Rear Suspension Installation 8 17 Rear Suspension Operation 8 14 Rear Suspension 8 17 Rear Suspension Ride Height 8 15 Rear Suspension Special Tools 9 2 Rear Suspension Weight Transfer 8 14 Rear Track Shock Pivot Orientation 8 3 Recoil Pulley Disassembly and Assembly 5 10 Recommended Engine Coolant 3 6 RMK FTA set up recommendations 8 16 5 Sciss
123. ilicone based or petroleum based Do not use brake fluid taken from old used or unsealed containers Never reuse brake fluid CAUTION Pressure bleeding is not recommended When fluid surges through the fittings it is possible to cavitate the fluid and create air in the system In addition the fluid stored in a pressure bleeder may be contaminated Al ways use fresh DOT 4 brake fluid from a sealed con iner 2 Remove the 20 Torx screws from the cover Keep these points in mind when bleeding hydraulic brakes 3 Carefully remove the cover and diaphragm assembly from the reservoir The master cylinder reservoirs have limited capacities 4 Under the cover inspect the vent slots under the bellows It is easy to empty them during the bleeding procedure and remove any debris or blockage This introduces air into the system which you are trying to purge Watch the reservoir closely and add fluid when necessary to prevent air from entering the system A Bleed or replace the fluid by attaching a clear hose from the caliper bleeder fitting to a clean container Be sure the hose fits tightly on the bleeder fitting e Apply only light to moderate pressure to the lever or 6 Pump the brake lever few times and hold pedal when bleeding the brake system Extreme 7 11 Drive and Systems 7 Slowly open the bleeder fitting and let the old fluid air escape 8 Pump the
124. imits AC Voltage to 14 3 volts The module also supplies 12 Vdc to power the exhaust valve solenoid Replace the regulator rectifier if the AC Voltage is above 14 8 V or when there is no 12 Vdc supply on the RED GREEN circuit Circuit Specifications PLUG COLOR FUNCTION YELLOW REGULATED 14 3 Vac POWER RED GREEN VALVE SOLENOID POWER BROWN GROUND DETONATION CONTROL DET 2008 600 RR Overview Detonation control is achieved by using a knock sensor mounted to the cylinder head and an ECU CFI engines or the CDI 600HO engines The knock sensor listens for combustion knock by converting internal engine noise in to an electrical signal The ECU or CDI uses the signal to determine the level of knock within the combustion chambers after each combustion event When the ECU or CDI determines detonation has occurred the CHECK ENGINE DET LED lamp will blink on and off at 0 5 second intervals On CFI models the ECU will retard timing and provide additional fuel to eliminate the detonation On carbureted engines the CDI will retard timing until the detonation stops If the detonation continues past a pre determined level the ECU or CDI will initiate an engine mis fire mode To prevent detonation follow these steps Always use premium fuel 91 92 or 93 octane On carbureted engines follow the carburetor jetting guidelines Do not modify the engine or exhaust system with non approved P
125. ine of a vehicle is operated under a wide range of conditions from idling with the throttle valve remaining almost closed to full load or maximum output with the throttle valve fully opened In order to meet the requirements for the proper mixture ratio under these varying conditions a low speed fuel system or pilot system and a main fuel system are provided in Mikuni type carburetors The Mikuni carburetor has varying operations depending upon varying driving conditions It is constructed of a float system pilot system main system and starter system or initial starting device Float System The float system is designed to maintain a constant height of gasoline during operation When the fuel flowing from the fuel pump into the float chamber through the needle valve reaches the constant fuel level the floats rise When the buoyancy of the float and the fuel pressure of the fuel pump balance the needle valve sticks fast to the needle seat preventing further delivery of gasoline thereby holding the standard level of gasoline The fuel level in the bowl assists in controlling the amount of fuel in the fuel mixture Too high a level allows more fuel than necessary to leave the nozzle enriching the mixture Too low a level results in a leaner mixture since not enough fuel leaves the nozzle Therefore the predetermined fuel level should not be changed arbitrarily PERFORMANCE gt POLARIS Fuel Metering THRO
126. is Carbon Clean If Polaris Carbon Clean is not used fuel tank fuel lines and carburetor should be completely drained of gasoline Corrosion To prevent corrosion always grease jackshaft and drive shaft clutch side bearings with Polaris Premium all season grease Loosen driven clutch retaining bolt and pull clutch outward to expose bearing Use a point type grease gun fitting to inject grease through hole in flangette into bearing until grease purges out inside or outside bearing seal Push clutch back on shaft and replace clutch retaining bolt Inject grease into fitting on speedometer drive adaptor until grease purges out inside or outside the bearing seal Lubricate both front ski pivots at bushings and spindles Shocks Use T 9 Metal Protectant or equivalent on shock absorber shafts to help prevent corrosion Battery Disconnect and remove the battery Clean the terminals and cables Apply dielectric grease to the terminals Store in a cool dry place for storage WINNING PERFORMANCE gt POLARIS Fuel Systems CHAPTER 4 Fuel Systems SERVICE WARNINGS AND PRECAUTIONS 4 2 SERVICE WARNINGS 5 2 5 2 72 ce ou p um Dude pQ SCR Bre 4 2 CARBURETOR FUELSYSTEMS 4 3 MIKUNIFMAIN 4 3 MIKUNEPIEOQT JETS 4 3 WIKUNISTARTER GES rreri
127. ise so that the shock rod 2 is facing upward 6 Reinstall the protective boot and carefully reinstall shock 4 Slowly loosen the shock rod bearing cap 4 and remove from the shock 5 Empty all the shock oil from the shock body and discard the old oil 6 Inspect the valve stack 5 as needed Replace any worn wavy bent valve shims 7 If valve shim service or adjustment is done torque the POLARIS Shocks Walker Evans Remote Reservoir Piggy Back Shock Disassembly NOTE Remote reservoir shock show IMPORTANT To prevent damage or marks to the shock the use of soft jaws on a vise is recommended 1 Clean and carefully remove shock from the suspension Remove button head screw 1 from reservoir cap if applicable Press the end cap into the reservoir to access the snap ring 5 Remove the snap ring then remove the cap from the body 9 10 6 Place the shock lower eyelet in a vise 7 Loosen and remove the bearing cap from the shock 8 Remove the used oil from the shock body NOTE Insert the IFP tool PN PS 45908 and cycle the internal floating piston IFP a few times to purge the shock oil from the reservoir 9 Remove the IFP from the reservoir with the IFP tool PN 5 45908 10 Clean and inspect ALL parts and replace worn parts if needed IMPORTANT Seal kits are available and should be installed at this time if seals or o rings are damaged worn 1
128. istance values within specs Isolate which component s resistance 15 not within specs Remove the flywheel and stator Recheck the resistances look for pinched or bare harness wires or replace the coil Incorrect Timing Follow the engine timing procedure for checking running timing at recommended RPM Is the timing within limits Remove the ignition kill circuit by disconnecting the single black wire between the CDI module and the machine harness Is the timing now correct Verify the correct CDI module by comparing the code on the box to the information listed in the ignition data charts at the beginning of this section Is it the right module Check the resistance of the coils under the flywheel Compare these to values on wiring diagram Are they within limits Wik NING PER FOR CE POLARIS Check the ignition switch wire harness throttle safety switches and kill switch for proper adjustment or short to ground Repair or replace as necessary Replace ignition regulator rectifier with a new part Re test If DC voltage is still not present test the stator charge coil Blue and Green circuits for AC voltage using a peak voltage reading adapter Continue tests in left side of table If the parts of the ignition system under the flywheel check OK the only remaining component is the coil CDI module assembly Replace the module with another with the same number Adjust the ignition timing by rotating
129. it with a new one Be sure the mating surfaces around the gasket are clean and smooth in order to avoid leaks CAUTION Some procedures will require removal of retaining rings or clips Because removal weakens and deforms these parts they should always be replaced with new parts When installing new retaining rings and clips use care not to expand or compress them beyond what is required for installation CAUTION Because removal damages seals replace any oil or grease seals removed with new parts CAUTION Polaris recommends the use of Polaris lubricants and greases which have been specially formulated for the top performance and best protection of our machines In some applications such as the engine warranty coverage may become void if other brands are substituted CAUTION Grease should be cleaned from parts and fresh grease applied before reassembly of components Deteriorating grease loses lubricity and may contain abrasive foreign matter 2 11 General Information NO TES POLARIS Maintenance CHAPTER 3 Maintenance PERIODICMAINTENANGE 3 2 PERIODIC MAINTENANCE SCHEDULE 3 2 MAINTENANCE PRODUCTS 20259 Ee fede meee hee abt eure ha 3 4 ENGINE OILS LUBRICANTS MISC 3 4 DRIVE 3 5 BELT DEFLECTION INSPECTION 3 5 DEFLECTION ADJUSTMENT TEAM DRIVEN 3 5 T
130. ive and Systems 21 Lock the parking brake 22 Replace the top sprocket retaining nut Torque to 50 ft Ib T Top Sprocket Nut 50 6 8N m 23 Install cotter pin and bent the ends around the jackshaft end 24 Install the lower sprocket retaining bolt Torque to 19 21 ft Ib 26 28 N m Bottom Sprocket Bolt 19 21 ft lb 26 28 N m 25 Release the parking brake 26 Adjust the chain tensioner by hand and back off 1 4 turn 27 Lock the adjuster lock nut 28 Install the chaincase cover and torque the cover bolts to specification Chaincase Cover Bolts 8 11 29 Remove the dipstick and fill chaincase with Polaris 80W Synthetic Chaincase Lubricant 30 Check for leaks 31 Adjust track tension to the specified tension 32 Reinstall the chassis components and exhaust system WIHNHINMSG PEA F R AA EE gt POLARIS Chaincase Seal amp Bearing Replacement Remove the chaincase as described above Pry out the old seals from the back side of the chaincase Remove bearing retaining snap rings Press out the old bearings from the back side of the chain case so that the bearings drop out of the front If the bearing pushes out hard warm the area to expand the chaincase bore slightly NOTE When removing always push out the bearing towards the snap ring side of the chaincase 5 Clean the chaincase 6 Apply Loctite 680 to the outer
131. k nuts with rod ends perpendicular to tie rod A 28 Ft Lbs 38 Nm 11 Ft Lbs 15 Nm Rod end jam nuts C 2 35 Ft Lbs 47 Nm Apply Loctite 262 to threads D 40 Ft Lbs 54 Nm NOTE Orientate rod ends so they are parallel with mating component gt POLARIS 8 7 Steering and Suspensions Handlebar Assembly HANDLEBAR CLAMP BRACKET x 7 STEERING POST T 15 17 Ft Lbs 20 23 Nm 8 8 WIMMING PERFONRMAMNMGE POLARIS Steering and Suspensions ADJUSTMENT PROCEDURES SETUP AND ADJUSTMENTS Spring preload is the amount of pressure at which the spring 15 held The longer the installed length of the spring the less the amount of preload the shorter the installed length of the spring the more the amount of preload An increase IFS shock spring preload will result in an increase in ski pressure To adjust front spring preload on threaded adjust models grasp the spring and turn in a clockwise direction as viewed from the top of the shock to increase the preload Turn in a counterclockwise direction to decrease preload Always set the preload equally between the right and left side shocks For the best ride the spring preload should be as low as possible Set the preload to use the full travel of the ski shock with occasional light bottoming CAUTION If the plastic nut is unscrewed from the threaded body the nut will break Always leave one
132. lean them out 15 Remove the air jet screw if so equipped 10 Remove water trap drain plug 15 and single screw 16 on the bottom of the carburetor 16 Clean out all passages in carburetor body with carburetor 11 Remove and drain the float bowl 17 cleaner Dry all passages and jets with compressed air NOTE Float bowl will not come off unless the water 17 Replace gaskets and any parts that show wear or damage trap drain plug and screw are removed 18 Repeat steps 1 18 for disassembly for the other carburetor if needed Assembly Install the main jet 20 pilot jet 21 and starter jet 22 Install float needle amp seat assembly 19 Place carburetor in an inverted position Connect a pressure tester PN 2870975 to fuel inlet fitting Apply 5 psi pressure and observe for one minute The needle and seat should hold pressure indefinitely If the pressure drops carefully inspect the needle and the needle seat The needle can be replaced needle supplied with float and seat cp Dee 12 Remove the two screws 18 holding the float needle and seat assembly 19 in position and remove this assembly 13 Inspect the contents for wear and debris 5 Carefully inspect float bowl gasket and replace if necessary 6 Install float bowl 16 on carburetor with water trap drain plug 15 and single screw 16 on the bottom of the carburetor WINNING PERFORMANCE 4 11 C POLARIS Fuel Systems 10
133. ler Installation 6 16 Roller Removal 6 16 Spider Indexing 6 18 Drive Clutch Weights 6 6 Drive System Terminology Backshifting 6 2 Clutch Weight 6 2 Drive Spring 6 2 Driven Spring 6 2 Engagement RPM 6 2 Final Gearing 6 3 Helix Ramp 6 3 Low High Ratio Lines 6 3 Neutral Speed 6 2 Shift Out Overrev 6 2 Driven Clutch Removal 6 19 Driven clutch installation 6 19 Driveshaft and Jackshaft Assembly 7 8 Driveshaft Removal and Installation 7 9 E Electric Reverse PERC 11 10 Electrical Specifications 11 2 Engine and Vehicle Break In Procedure 2 2 Engine Component Assembles 600 RR IQ Racer Water and Oil Pump 5 21 600 RR Crankcase 5 25 600 RR Cylinders Cylinder Head 5 22 600 RR Pistons Crankshaft 5 24 600 RR Recoil Magneto 5 23 IQ Racer Crankcase 5 20 IQ Racer Cylinder Head Cylinders 5 17 IQ Racer Piston Crankshaft 5 18 IQ Racer Recoil Magneto 5 19 Variable Exhaust System VES 5 26 Engine Component Assemblies 600 RR Engine Mounting 5 15 Engine Bulkhead 5 16 IQ Racer Engine Mounting 5 14 Engine Data Formulas 2 9 Engine Inspections 5 4 Cylinder Head 5 4 Engine Installation 5 12 Engine Removal Engine Specifications Component Torque Sequences 5 2 D
134. line see your doctor immediately Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing POLARIS Fuel Systems CARBURETOR FUEL SYSTEMS Mikuni Main Jets oc oc oc oc m m m 2 z z d d d lt Mikuni Pilot Jets STARTER JET PART NUMBER 3130770 3130771 3130772 8 Ae Mikuni Starter Jets 3130805 3130767 3130768 3130769 POLARIS Fuel Systems Mikuni Jet Needles J8 9DGN6 57 3131438 Mikuni Short Pilot Air Jets AIR JET PART NUMBER 3130773 o5 feom Mikuni Piston Valves Mikuni Notched Piston Valves WINNING PERFORMANCE gt POLARIS Fuel Systems MIKUNI TM CARBURETOR Function The function of a carburetor is to produce a combustible air fuel mixture by breaking fuel into tiny particles in the form of vapor to mix the fuel with air in a proper ratio and to deliver the mixture to the engine A proper ratio means an ideal air fuel mixture which can burn without leaving an excess of fuel or air Whether the proper mixture ratio is maintained or not is the key to efficient engine operation The eng
135. lippage occurs in the drive clutch Once 100 belt engagement is achieved the sled will accelerate along the low ratio line until the drive clutch up shift force overcomes the opposing shift force generated by the driven clutch Shift Out Over Rev Engine RPM that spikes above the desired operating RPM speed The shift out RPM should come down to the desired operating RPM but never below after the driven clutch begins to open Shift Out RPM Engine RPM at which the up shift force generated by the drive clutch overcomes the shift force within the driven clutch In this mode the drive clutch will move the belt outwards and the driven clutch will allow the drive belt to be pulled down into the sheaves During WOT operation the shift out RPM can be seen as the maximum sustained RPM displayed on the tachometer The shift out RPM should be the same RPM as the recommended engine operating RPM If the shift out RPM is above the recommended engine operating RPM install heavier drive clutch weights If the shift out RPM is below the recommended engine operating RPM install lighter drive clutch weights The shift out RPM should remain constant during both the upshift and back shift modes Driven Spring A compression spring Team driven clutch or torsional spring Polaris P 85 driven clutch works in conjunction with the helix and controls the shift rate of the driven clutch The spring must provide enough side pressure to grip the be
136. load on the spring transfers more weight to the track A softer spring and or less preload keeps more weight on the skis Keep your riding application in mind when choosing springs and setting spring preload Soft springs preload will increase ski pressure but may bottom out Stiff springs preload will provide more track pressure reduced ski pressure but may result in a less comfortable ride During acceleration the rear of the suspension will compress and the IFS will extend pivoting the machine about the front torque arm Because of this pivoting effect rear spring and spring preload also have some effect on weight transfer Softer rear springs or less preload allow more weight transfer to the 8 14 track and reduce ski pressure Stiffer rear springs or increased preload allow less weight transfer to the track and increase ski pressure The main function of the rear torque arm is to support the weight of the vehicle and rider as well as to provide enough travel to absorb bumps and jumps Shock valving also has an effect on weight transfer Refer to shock tuning information in this chapter Scissor stops also affect weight transfer See scissor stop information also in this chapter 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 couplin
137. lt and prevent slippage during initial acceleration A higher spring rate will provide more side pressure and quicker back shifting but decreases drive system efficiency If too much spring tension exists the driven clutch will exert too much force on the belt and can cause premature belt failure Back Shifting Back shifting occurs when the track encounters an increased load demand for more torque Back shifting is a function of a higher shift force within the driven clutch then within the drive clutch Several factors including riding style snowmobile application helix angles and vehicle gearing determine how efficient the drive system back shifts The desired engine operating RPM should never fall below 200 RPM when the drive system back shifts PER FOR gt POLARIS PVT System Final Gearing The final drive gear ratio plays an Important role In how much vehicle load is transmitted back to the helix tall gear ratio lower numerical number typically results in lower initial vehicle acceleration but a higher top end vehicle speed A lower gear ratio higher numerical number typically results in a higher initial vehicle acceleration but a lower top end vehicle speed Choosing the proper gear ratio 1s important to overall drive system performance When deciding on which gear ratio to use the operator must factor in the decision where the snowmobile will be ridden what ty
138. m 2 90 73 8 Stroke inches mm 2 75 70 Piston to Cylinder Clearance 0034 005 088 129 inches mm 014 022 036 56 inches mm Operating RPM 200 8250 1800 2400 430 420 400 390 370 360 340 330 Idle RPM 1500 6000 8000 3 2 2 2 1 1 5 5 8000 10 000 3000 3700 370 360 340 330 310 300 280 270 Carburetor Settings 10 000 12 000 2 2 2 1 1 5 5 5 NOTE Needle position 5 plastic washer Clutch Settings Jet Needle Clip position OFH4 57 2 Throttle Gap Under Cutaway in mm Ment Spring Spring Helix 0 900 TUR 0 3000 900 1800 10 56 3000 6000 4 160 280 Almond Red Black 70 44 46 19 45 _ 76 5 4 3 3 2 2 1 600 1200 490 480 460 450 430 420 400 38 2000 000 H3 3 2 2 2 2 1 1200 1800 460 450 430 420 400 390 370 36 4000 6000 3 3 2 2 2 1 1 Fuel screw Turns Out Recommended Fuel Octane R M 2 No genated 1800 2700 7041988 7043252 66 44 46 6000 9000 2700 3700 9000 12 000 9 AL Drive Clutch Bolt Torque 50 Ib ft 68 Nm 14 POLARIS Model Specifications General Front Suspension Walker Evans 16 Position Shocks Compression Adjustable Remote Reservoir Race Valving IFS Spring Rate Spring Installed Length m 12 00 30 5 Width in cm 48 122 Length in cm
139. magnetic tip 2 on the dipstick Reinstall the dipstick ee aoe ee WINNING PERFORMANCE gt POLARIS Maintenance Chaincase Oil Replacement 1 Locate the chaincase or gearcase drain plug access hole the bottom of the nosepan Place an oil catch pan under the drain plug 2 3 Remove the drain plug and drain the oil into the catch pan 4 Clean the magnetic plug to remove metal shavings 5 Install drain plug and hand tighten Do not over tighten the drain plug 6 Fill chaincase or gearcase at the dipstick hole Chaincase Oil Capacity 902 266 2 ml Recommended Lubricants Chaincase Polaris Synthetic Chaincase Lubricant Drive Chain Tension Adjustment 1 Rotate the driven clutch counterclockwise to move all of the slack in the chain to the tensioner side Lock the parking brake or have an assistant hold the brake lever Loosen the adjuster bolt jam nut 1 3 Finger tighten the adjuster bolt 2 until it can no longer be adjusted by hand then back 1 4 turn 4 Tighten the jam nut while holding the adjuster bolt Torque to 21 ft lbs 28 Nm 5 Release the brake lever lock PERFORMANCE POLARIS BRAKE SYSTEM MAINTENANCE Brake Lever Travel The brake lever travel should have clearance no less than 1 2 1 27cm from the handlebar grip Inspection should be made with the lever firmly depressed If the lever has less than this amount you
140. may need to bleed the brake system Brake Fluid A WARNING Do not over fill the master cylinder Fluid expansion could cause brakes to lock resulting in serious injury or death Once bottle of brake fluid is opened use what is necessary and discard the rest Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air This causes the boiling temperature of the brake fluid to drop leading to early brake fade and the possibility of serious injury Inspect the reservoir to be sure it contains the correct amount of fluid Use only Polaris DOT 4 high temperature brake fluid Change fluid every 2 years or whenever the fluid is dark or contamination is suspected NOTE A low brake fluid level can be indicated through the sight glass on the cover If the fluid is low this sight glass will glow a brighter color 3 9 Maintenance THROTTLE AND CHOKE CABLE 4 Set the throttle lever free play by loosening the throttle ADJUSTMENTS cable jam nuts Idle Speed Gap Throttle Free Play Adjustment CAUTION When adjusting throttle lever free play always verify the engine idle RPM does not increase when turning the handle bar to the full left or full right positions After idle speed adjustments are made the throttle lever clearance and oil pump adjustment must be checked and adjusted Throttle Lever Free Play 1 Always set the idle speed when the
141. n Corporation WINNING PERFORMANCE a a 4 lt a 2008 600 RR IQ Racer Service Manual Chapters Model Specifications 1 General Information 2 3 Fuel 4 Engine 5 5 5 Final Drive and Brake Systems 6 PVT System 7 Suspension and Steering 8 ShockS wees 9 ChassiS er 10 Electrical Systems 11 Wiring Schematics 12 Model Specifications CHAPTER 1 1 Model Specifications SPECIFICATIONS Suid IS ta 1 2 2008 COON RR 1 2 2008 600 19 1 4 gt POLARIS 1 1 Model Specifications SPECIFICATIONS Carburetor Jetting Ambient Temperatur 2008 600 RR LL T Model Number S08MX6FS SO8SMX6FE Altitude Engine Meters feet Basie Type Liberty Liquid Cooled x ve Case Reed Induction Model Number 53649 6044 PU6F lt 25 F lt 35 C 30 F to 10 F 34 C to 23 C 15 F to 5 F 26 C
142. n system begins to take effect as soon as there is enough air flow into the carburetor venturi to draw fuel up through the main jet and needle jet assembly This system works in conjunction with the needle jet system During low speed driving there is very little clearance between the jet needle and the needle jet therefore very little fuel from the main jet can pass between the jet needle and the needle jet As the throttle valve opening is increased the tapered jet needle is raised farther out of the needle jet allowing greater fuel flow Under full throttle opening the cross sectioned area of clearance between the jet needle and the needle jet becomes greater than the cross sectioned area of the main jet Thus the main jet is now controlling the amount of fuel flow Pilot Jet From idling to low speeds the fuel supply is metered by the pilot jet There are several air bleed openings in the sides of the pilot jet which reduce the fuel to mist The number stamped on the jet is an indication of the amount of fuel in cc s which passes through the jet during a one minute interval under a given set of conditions Fuel Screw The fuel screw controls the fuel mixture from idle to low speeds The tapered tip of the fuel screw projects into the passage leading to the by pass out let By turning the screw in or out the cross sectional area of the air passage is varied in turn varying the fuel screw varies the amount of air fuel Main Jet
143. ng This system also incorporates a diaphragm E as part of the cover gasket and a vent port on cover located between the gasket and the cover The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts Be sure the vent is open and allowed to function If the reservoir is overfilled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system and lead to brake failure PERFORMANCE gt POLARIS Drive and Systems General Guidelines pressure will cause a surge of fluid through the small orifices of the brake system when the bleeder screw is opened and introduce air into the system by means of A WARNING unsafe condition exists when air is trapped the Small amounts of air can become trapped in the banjo hydraulic brake system Air in the brake hydraulic sys bolt fittings at the master cylinder s and junction points tem acts like a soft spring and absorbs a large percent of brake lines These fittings can be purged of air by age of the pressure developed by the master cylinder following a standard bleeding procedure at these Without this pressure the braking system cannot de fittings instead of the bleed screw on caliper if velop full braking force to allow for safe controlled necessary to speed the bleeding process This is usually stops It is extremely important to bleed the brak
144. ng Place bolt inside weight to check flyweight bushing and pin surface for wear by rocking the weight back and forth 17 Inspect all the rollers bushings and roller pins by pulling a flat metal rod across the roller 18 Roller can also be inspected by rolling with a finger to feel for flat spots roughness or loose bushing NOTE The flyweight bushing is not replaceable If flyweight bushing is damaged both the flyweight pin and nut will need to be replaced 19 Inspect to see if the roller and bushing are separating 20 Bushing must fit tightly in roller 21 Replace roller and pin if roller fails to roll smoothly no flat spots or if the bushing is loose or worn 6 15 PVT System Roller Removal ROLLER WASHER 1 With the spider in a vise start removing the spider buttons by drilling a 0 18 hole in the center of a button on one side of the spider Place spider on a vise or in an arbor press 3 Place a pin punch through the spider button hole and drive the opposite button and pin out Remove shims if any are installed and note their location 5 Flip the spider over and tap out the holed button Roller Installation NOTE Use care to start the pin straight Aluminum burrs could pass through into the roller bushing causing it to bind and stick Also use care to make sure the roller remains aligned when the pin is driven through The roller busing could be damaged causing premature wear and r
145. ng Ryde FX gas charged mono tube shocks When removing the spring from a shock that utilizes a fixed lower retainer the use of a proper spring compressor should be used to avoid risk of bodily injury lt is important that the gas shock be retained in the vise by the lower mount Any other method of securing the chock body during these procedures may deform the shock body cylinder Point air valve away from face and body when charging or discharging any shock Shock Maintenance Changing oil on Shocks is recommended annually and should be included when performing end of season storage preparation This oil change is necessary to avoid any chance of corrosion which could be caused by moisture contamination When performing maintenance use Gas Shock Recharging Kit PN 2200421 The kit consists of the necessary valves pressure gauge and fittings to deflate and pressurize the shocks The Body Holder Tool Internal Floating Piston IFP and Shock Rod Holding Tool are not included in the Recharging Kit and must be ordered separately Refer to your SPX Specialty Tool catalog for part numbers Videos on shock rebuilding are also available Monotube shocks 9917736 Remote Reservoir 9917737 WINNING gt POLARIS Shocks Walker Evans Air Shock Disassembly piston retaining bolt 6 to 25 30 ft Ib 34 41 N m IMPORTANT Verify the protective outer boot is not torn or damaged If damaged inspect the
146. nment tool will not work with a standard Team driven clutch A Team LW driven clutch can be identified as having 24 cooling fins 3 The optimum setup is when the front and rear of the tool touch the driven clutch No gap should be present in the front and the rear clearance should not exceed 060 3mm NOTE If the front of the alignment bar does not touch the driven sheave the maximum clearance cannot exceed 025 Offset Adjustment 1 Determine direction driven clutch needs to be adjusted Remove driven clutch retaining bolt and remove driven clutch 3 Add or remove washers from the jackshaft between the driven clutch and jackshaft bearing to achieve proper offset 4 After adjusting offset add or remove shim washers from the retaining bolt to provide a 0 030 75mm of float on the jackshaft CAUTION Always verify the driven clutch floats on the jackshaft after securing the fastener The jackshaft bearing will fail due to side loading if the driven clutch is not allowed to float WINNING gt POLARIS 0 060 Touching BW PN PS 46998 Shown 6 13 PVT System DRIVE CLUTCH Identification Every clutch will have the last three digits of the clutch part puller and repeat this step number etched on to the cover A The X B marking is an index mark where the clutch cover C clutch spider D and the stationary sheave E sho
147. nstall needle bearing and pin in connecting rod 4 Rotate pin slowly and check for rough spots or any resistance to movement 5 Slide pin back and forth through bearing while rotating and check for rough spots 6 With pin and bearing centered in rod twist ends back and forth in all directions to check for excessive axial play 7 Replace pin and bearing if there is any resistance to rotation or excessive axial or radial movement If play or roughness is evident with a new pin and bearing replace the connecting rod Crankshaft Index Polaris crankshafts are pressed together The connecting rod journal center lines are indexed 180 apart from each other Itis sometimes necessary to check multi cylinder crankshafts to verify that one cylinder has not been forced out of position relative to the other cylinder Some causes for of index crankshaft include but are not limited to the following Hydrolock from water or fuel mpact to drive clutch from object or accident Abrupt piston or other mechanical failure Engine lock up due to drive belt failure Symptoms of an out of index crankshaft can include but are not limited to the following Difficulty calibrating carburetor repetitive plug fouling on one cylinder with no other cause Unexplained piston failure on one cylinder 1 e severe detonation broken ring lands etc Excessive vibration of engine back firing etc Rough idle poor top
148. ol PN 2201519 is used to accurately adjust the TPS return signal settings TPS Test Tool Setup The test tool must be always be used to inspect the TPS on carbureted engines On CFI models either the test tool or Digital Wrench can be used to test the TPS NOTE Signal readings can be affected if the 9 volt battery is weak Always verify the battery is in good condition 1 Set the multimeter to read Vdc Verify the 9 volt battery condition by inserting the black multimeter probe into the black wire terminal and the red multimeter probe into the pink wire terminal Voltage should read 4 99 to 5 01 Vdc Use a new battery if voltage is below 4 99 Vdc Black Red Pink WIHNING POLARIS ELECTRICAL SYSTEMS 3 Connectthe test tool to the TPS on the carburetor or throttle body NOTE Always disconnect the 9 volt battery when tool is not in use Using the TPS Test Tool 1 Remove the wiring harness connector from the TPS Verify the throttle cable is not kinked and the throttle flipper is closed Disconnect the throttle cable from the throttle flipper 3 Connect the test tool to the TPS Insert the black multimeter probe into the black terminal port then insert the red multimeter probe into the yellow terminal port 5 Reference the specifications to determine if the TPS requires adjustment or replacement 6 Reconnect the throttle cable with throttle flipper TPS Setting Spec
149. olaris modifications Verify there is no water or foreign material in the fuel Verify there is no internal engine damage Verify the cooling system is working properly CE POLARIS NOTE Install the knock sensor fastener clean and dry without applying thread locker or oils VARIABLE EXHAUST SYSTEM VES Overview The Polaris VES system uses exhaust valves 1 per cylinder to control the exhaust port height The valves are actuated by controlling cylinder pressure with a solenoid bellows and a series of hoses At idle speed and up to a pre determined level the solenoid s ground path is closed by the CDI This action opens the solenoid s internal valve and allows the cylinder pressure to vent into the atmosphere During this time the valves are down To raise the valves the CDI will cut the solenoid ground path which will close the vent path to atmosphere The cylinder pressure will then act upon each valve bellows which will raise each valve On 600 RR engines the CDI will turn the solenoid off at 6700 RPM when the throttle flipper is at least 3 4 throttle or at 7200 RPM when the throttle flipper is at least 1 2 throttle On 600 Racer engines the solenoid is off at any RPM whenever the throttle lever is below 100 open When the throttle lever is at 100 WOT the solenoid remains powered until 7100 RPM NOTE Solenoid Powered Vent Path Open S
150. olenoid Off Vent Path Closed 11 9 ELECTRICAL SYSTEMS ELECTRONIC REVERSE PERC Operation A WARNING Reverse operation even at low speeds may cause loss of control resulting in serious injury or death To avoid loss of control always LOOK BEHIND BEFORE AND WHILE BACKING AVOID SHARP TURNS SHIFT OR FROM REVERSE ONLY WHEN STOPPED APPLY THROTLE SLOWLY CAUTION To avoid personal injury and or engine damage do not operate the electric start or recoil while engine is running 1 Ensure that the vehicle is stopped and the engine is warmed up and running at idle NOTE The system will only engage in reverse if the engine is below 4000 RPM If engine is above 4000 RPM the system can not be activated Ensure that the path behind you is clear 3 Push and hold the yellow reverse button on left hand control for 1 second and then release the button The reverse light on the instrument panel will flash when engine is in reverse motion NOTE The engine will automatically reduce RPM and it will reverse the rotation of the engine when the RPM 15 at the lowest RPM point 4 Ensure that the path behind you 15 clear 5 Slowly apply throttle until the sled starts to move in reverse and carefully direct the sled in the direction that you want NOTE Maximum RPM in reverse is 6000 RPM NOTE If the engine stops running or is shut off while in reverse The engine will start in forward gear For
151. oller failure 1 Drive pin into the spider leg 100 125 0 25 0 32cm beyond the first land of the spider leg 2 Install one washer on the portion of the pin that is protruding from the spider leg Install new buttons into the spider Place roller in spider leg and center it on the pin Place a second washer on the other side of the roller Place the spider on a vise Install pin centering tool PN 2870401 Drive the roller pin through the second land of the spider NAAR Repeat process other two 6 16 10 Measure the width of the spider lee with the buttons installed 9 and record the measurement Specification 15 1 496 37 99mm 11 Measure the width of the moveable sheave towers Specification is 1 50 38 1mm 12 Subtract the spider measurement form the tower measurement The clearance between the spider buttons and the moveable sheave towers is 002 004 05 PERFORMANCE gt POLARIS PVT System Clutch Assembly 1 Assemble the rollers bushings and roller pins if they were removed 2 Install the head of the weight pin so that it is on the leading side of rotation This will orientate the nut on the trailing side of rotation 3 Torque weight pin to 30 in Ib 3Nm Place the moveable sheave onto the stationary sheave 5 Place the same number of spacers on top of the stepped spacer onto the sha
152. om the field The weekly racing report form is a valuable source of this data As a part of the Polaris team your input is highly valued and never ignored At Polaris we are committed to your racing effort We wish you the best of luck in the season ahead Please visit our web site for updated information throughout the racing season http www polarisindustries com en us snowmobiles racing Polaris Racing Department POLARIS RACING 10303 Calumet Ave Suite 1 Rothschild WI 54474 Phone 715 355 5157 Contact Tom Rager Jr EXT 11 Bill Rader EXT 12 Fax 715 355 8797 PARTS SUPPORT Brad Seavers Phone 715 355 3008 Fax 715 355 8797 SOUTHSIDE RACE SUPPORT Contact Bruce Gaspardi 546 Curran Hwy North Adams MA 01247 PHONE 413 664 7111 WEB www southsidesales com 2 2 2008 600 IQ RACER MODEL Overview The 2008 600 IQ Racer model has been designed and tested to endure the toughest of all races Many hours have gone into determining the overall best manufacturing setup based on average rider weight and typical riding environment All 2008 600 IQ Racer snowmobiles are setup as follows e Stock suspension and gearing is setup for a 170 Ib 77 18 kg rider Carburetor and clutching is setup for operation at 0 3 000 feet 0 900 meters Break In 1 Always break in any new part for 50 75 miles before using it for racing 2 Clutch springs and belts need to be broken in to reach
153. ommends using Polaris VES Gold Synthetic Two Stroke engine oil Never mix different brands of engine oil Exhaust Valve Housing Fasteners 12 Ft Lbs 16 Nm Apply Loctite 242 Oil Pump Adjustment 600RR FLOW MARK ALIGNMENT MARK NOTE Before adjusting oil pump always verify the throttle lever free play and idle speed RPM are set to specification 1 Verify the oil pump flow mark in line marker 1 aligned with the oil pump body mark at idle 2 Lever adjustment is accomplished by loosening the two oil pump cable jam nuts then moving the threaded barrel up or down until the two marker lines are aligned 3 Apply Loctite 262 to barrel threads and secure jam nuts when adjustment is set WINNING PERFORMANCE gt POLARIS Oil Pump Bleeding 1 Verify oil tank is filled with oil Loosen the bleed screw Verify a stream of oil flows from the bleed screw 3 Verify a stream of oil flows from the bleed screw After bleeding oil pump secure bleed screw and wipe up oil residue NOTE Any time that the engine is disassembled or repaired it is important to purge air within the hoses and oil pump Oil Fuel Filter CAUTION The in tank fuel filter and fuel lines should be inspected regularly Special attention should be given to the fuel line condition after periods of storage Normal deterioration from weather and fuel can occur during this storage period Do not damage fuel lines when removing th
154. or Stop Adjustments 8 15 Shock Maintenance 9 8 Shock Piston Orientation 9 5 Shock Specifications 9 6 Shock Valve Part Numbers Walker Evans 9 3 Walker Evans 7 16 ID 9 4 Shock Valve Stack Configurations 9 7 shock Valving Arrangement 9 5 Ski Skag Torque Adjustments 3 12 SK ASSembIy p rx ORE GEE 8 3 Spark Plug Reading 2 10 Spindle Assembly 8 10 Spindle Disassembly 8 10 Steering Post Assembly 8 5 Steering Inspection 8 2 Suspension Mounting Fastener Torque 8 3 Sache 11 8 ThermoStat riskon eto ERE 5 29 Throttle Opening vs Fuel Flow 4 7 Throttle Position Sensor 11 6 Toe Specifications 8 2 Torque Conversion Table 2 Torsion Spring Adjustments 8 16 Track AIgBImIeriE x uus ax added eames 3 13 Track Alignment Adjustment 3 13 Track Tension Adjustment 3 12 Trouble Shooting Electrical 11 11 U Upper Lower Control Arm Installation 8 10 Upper Lower Control Arm Removal 8 10 V Variable Exha
155. ostat 17 Disconnect the impulse line from the crankcase 18 Remove the recoil handle and secure the recoil rope 19 Disconnect the EV solenoid water pump sensor regulator rectifier and stator connections 20 Remove the PTO EV assembly from the engine mm 21 Remove the front motor mount fasteners and washers 22 Remove the rear motor mount fasteners 23 Remove the engine from the clutch side of the chassis Installation The following instructions is for an engine that is assembled with the engine mounting plates attached and the spark plugs and PTO EV assembly removed 5 12 NOTE Install the large flat washers onto the rear motor mounts before proceeding A v 1 W J lt e pe s p CD ri 1 5 0 Po wo E 4 M VP F K k 7 va ans 4 4 L ae 4 X j n y g F a d 1 From the clutch side place the engine into the chassis and onto the motor mounts PERFORMANCE gt POLARIS Engine and Cooling Systems 2 Apply Loctite 242 to the threads of each base fastener on 12 Replace the manifold and torque the mounting fasteners to the PTO EV and torque to specification specification 13 Replace the rear torque stop plate and torque the fasteners to specification EV B
156. ottle and holds the flipper at WOT When the drops the racer need only to release the Dragon Fire button The Dragon Fire system works by retarding the engine timing enough to accomplish two goals The first goal is to heat the exhaust pipe s center section to approximately 750 F 400 C The second goal is to hold engine RPM between 4500 and 5500 RPM NOTE Always test stock and modified clutch setups to verify clutch engagement does not occur below 4500 5500 RPM Solenoid Controlled Exhaust Valves Each variable exhaust valve is controlled by a solenoid Each solenoid controls the vent path for each valve assembly The solenoids are normally closed when not powered by the CDI When closed cylinder pressure pushes up on each valve s bellows which opens the valve During engine operation the CDI cuts power to each solenoid at 6700 RPM Below 6700 RPM both solenoids are powered allowing cylinder pressure to bypass each valve s bellows which keeps each exhaust valve in the down or closed position 11 6 THROTTLE POSITION SENSOR TPS The TPS is located on the carburetor rack carbureted engines or on the throttle body CFI engines The TPS is set at the time of manufacture and should only require adjustment when When the TPS is replaced When the carburetor rack or throttle body is replaced or adjusted The TPS is suspected of being set incorrectly as part of troubleshooting The TPS test to
157. ove the oil pump cover remove the two fasteners then pull the pump cover out of the crankcase bore Discard the gasket The cross shaft can be extracted from the water pump side of the crankcase Assembly is the reverse of disassembly Always use new o rings seals and gaskets during assembly Install a new seal onto the shaft from the water pump side To install a new water pump seal use the seal installation tool PN 2872010 Verify the seal lips are facing the cross shaft gear 5 21 and Coolinq Systems 600 RR Cylinders Cylinder Head BLEED SCREW THERMOSTAT Li HOUSING THERMOSTAT SENSOR SENSOR D A 70 In Lbs 8 Nm B 9 Ft Lbs 12 Nm Apply Loctite 242 C 25 Ft Lbs 34 Nm Apply Loctite 242 D 18 Ft Lbs 24 Nm Apply Pipe Sealant E 168 In Lbs 19 Nm Clean and Dry F 37 Ft Lbs 50 Nm Disassembly Assembly Process 1 Remove the coolant from the engine using a siphon wet dry vac or drain pan 2 Remove the air box exhaust pipe and resonator from the engine compartment 3 Remove the high tension wires and spark plugs from the cylinder head 4 Remove the thermostat housing outlet cooling hose from the housing 5 Loosen all then remove all head cover fasteners Clean the fastener threads to remove any thread locking residue 6 Discard the head cover and cylinder head o rings Always use new o rings during assembly
158. p amonio sr um T i081 TG 120 xosmas wv __ i oe ee 3wW8 Pwo tive 39NW0 1109 wii SIMON Som amonio Z mE E E 4091 MOTA 8 QNO HOSN3S 130 wOSN3S 130 301000 102 9 2 9103108 9 sSsswvg 102 90 120 psg 9 9 0 81 mi 610 321145 SISSVH2 mona mu 391195 SISSVH2 3081 motii 91 x 910 ___ _____321145 515 901 sio 4081 fd HDLIMS 330 1095 3NION3 211 5 42v 18 81 10 NOTLINOI SSINUVH 102 ________ ____ ______ _ __ ______ 1 GOOH SISSVHD 3 SS3NNH 1l e dW3l U3iVM 3NION3 SISSVH iod __ 81 0341010 93 1 X 8 102 Tu 600 WNOIS 3Su3A3H 3NION3 SISSVH 3XMOON 10 9 13 3IGI9IK CI IIIIH 8
159. pe of riding will be encountered and the level of performance the operator hopes to achieve Gearing a snowmobile too low for extended high speed runs may cause damage to the drive belt and drive system while gearing a snowmobile too high for deep snow mountain use may cause premature belt and clutch wear Typically it is recommended to gear the snowmobile with a slightly higher ratio than the actual top speed the snowmobile will ever achieve 1 1 Shift Ratio A 1 1 shift ratio occurs when the drive clutch and the driven clutch are rotating at the same RPM The mathematical vehicle speed for a given gear ratio at a 1 1 shift ratio is represented in the chaincase gearing charts located in the Final Drive Chapter Low High Ratio Low ratio is the mechanical position when the drive belt is all the way down into the drive clutch and all the way out on the driven clutch High ratio represents when the drive belt is all the way out on the drive clutch and all the way in on the driven clutch Driven Helix Ramp The helix cam is the primary torque feedback component within the driven clutch regardless of driven clutch type The beginning angle of the helix must transmit enough torque feedback to the moveable sheave in order to pinch the drive belt while minimizing belt slip The flatter or lower the helix angle the more side force will be exerted on the moveable sheave while the steeper or higher the helix angle the less sid
160. performance of your engine That is why using Exhaust Gas Temperatures EGT are important for maintaining optimum performance There are two methods for helping you determine what the EGTS are for your machine Piston wash and the coloring of your spark plug The piston wash is by far the most valuable tool in concluding EGIS with the spark plug color running a distant second Use the illustrations below to help you establish the EGTS for your machine Once the proper jetting is established you can reference the EGT gauge for your baseline numbers Then if there is a rise or fall of 25 degrees you must jet accordingly to return your EGTS to the baseline numbers Piston Wash Spark Plug Color WINNING P E H FORMANCE POLARIS SERVICE PRECAUTIONS GENERAL PRECAUTIONS In order to perform service work efficiently and to prevent costly errors the technician should read the text in this manual thoroughly familiarizing him herself with procedures before beginning Photographs and illustrations have been included with the text as an aid Notes cautions and warnings have also been included for clarification of text and safety concerns However a knowledge of mechanical theory tool use and shop procedures is necessary to perform the service work safely and satisfactorily Use only genuine Polaris service parts CAUTION Cleanliness of parts and tools as well as the work area is of primary importance Dirt and foreign matter
161. r full neutral position Place a straight edge across the tow clutches on top the belt 3 Apply downward pressure to the belt and measure the distance at point D WINNING PERFORMANCE gt POLARIS Maintenance 4 The measurement should be 1 1 4 3 2cm Belt Deflection 1 25 3 2cm 5 Ifthe measurement is not correct adjust driven clutch Deflection Adjustment Team Driven 1 Verify the drive system is FWD drive by rotating the driven clutch forward 2 While holding the set screw with an Allen wrench loosen the jam nut 3 Turn the set screw clockwise while holding the jam nut stationary to increase the distance between the clutch sheaves increase belt deflection 4 Turn set screw counter clockwise while holding the jam nut stationary to decrease the distance between the clutch sheaves decrease belt deflection 5 Secure the jam nut while holding the set screw stationary 6 Raise the rear of the snowmobile using a track stand to allow the track to spin 7 Start the engine and apply enough throttle to spin the track 8 Turn off then engine then re check the belt deflection NOTE Do not adjust the belt deflection to the point where the drive belt cord line is visible when the belt is seated in the driven clutch 3 9 Maintenance Torque Stop Adjustment Set torque stop bumper gap to specification after aligning drive and driven clutches Torque Stop Bumper to Engine Gap
162. r to measure the runout at the following locations N e PTO end First taper after bearing flat e MAG end 1 2 from bearing flat 3 Runout deflection cannot exceed 0025 07mm 4 If the runout deflection exceeds the maximum specification crankshaft trueing may correct the deflection PERFORMANCE gt POLARIS Engine and Cooling Systems Piston Inspection Check piston for scoring or cracks in piston crown or pin area Excessive carbon buildup below the ring lands is an indication of piston ring or cylinder wear On Fuji engines measure piston outside diameter at a point that is 1 2 12 7mm up form the bottom of the skirt at a 90 angle to the direction of the piston pin DOMESTIC ENGINES Measure 3 8 10 0mm up from bottom of skirt FUJI ENGINES Measure 1 2 12 7mm up from bottom of skirt Subtract this measurement from the minimum cylinder measurement 90 to the pin If clearance exceeds the service limit the cylinder should be re bored replaced if Nicasil lined and new pistons and rings installed Piston Ring Installed Gap Piston Ring 1 2 1 3 1 2 Feeler Gauge Position the ring 1 2 1 3 cm from the top of the cylinder using the piston to push it squarely into place Measure installed gap with a feeler gauge at both the top and bottom of the cylinder NOTE A difference in end gap indicates cylinder taper The cylinder
163. ring and Suspensions CHAPTER 8 Steering and Suspensions OVERVIEW 8 2 8 2 TOE SPECIFICATIONS 8 2 8 2 SUSPENSION MOUNTING FASTENER 8 3 REAR TRACK SHOCK PIVOT 8 3 SKIASSEMBEY 8 3 FRONT SUSPENSION ASSEMBLY ILLUSTRATIONS 8 4 2008 IQ RACER 600 RR FRONT SUSPENSION 8 4 IO RACER 7 600 REESTEERING POST yuyu pat aps la 8 5 2008 IQ RACER STEERING ASSEMBLY th oret cesi recettes 8 6 2008 600 RR STEERING ASSEMBLY 8 7 HANDLEBAR ASSEMBLY 8 8 ADJUSTMENT PROCEDURE S qd 8 9 SETUP AND ADJUSTMENTS o vta orci d ERE 8 9 ALIGNMENT BAR SPECIFICATIONS us nci qat aea 8 9 ROD ENDS 8 9 ENGAGEMENT 8 9 HANDLEBAR CENTERING S n rer es haa let a 8 10 TOE ADJUSTMENT ies eda S botas oleis E Stud 8 10 DISASSEMBLY AND ASSEMBLY el 8 10 SPINDLE REMOVAL u destra 8 10 SPINDLE ASSEMBLY sya ntc fL p AM
164. ring the lower control arm LCA to the spindle Note the orientation of the fastener and nut 5 Remove the tie rod from the spindle by removing the nut and bolt Spindle Assembly 1 Assembly is the reverse order of disassembly Reference the front suspension assembly illustration for fastener torque values Spherical Bearing Replacement 1 Remove the fastener securing the lower control arm LCA to the spindle Remove the lower shock fastener 3 Remove the fasteners securing the LCA to the bulkhead 4 Remove the snap ring then using a press press the spherical bearing out of the LCA 5 Press in new bearing then install the snap ring 6 Assemble the LCA into the spindle and shock into LCA Reference front suspension assembly illustration for fastener torque values Upper Lower Control Arm Removal 1 Remove the fastener securing the control arm being removed from the spindle Remove the lower shock fastener 2 Remove the fasteners securing the control arm to the bulkhead 3 Remove the control arm pivot bushings and pivot shafts Upper Lower Control Arm Installation 1 Replace the upper or lower control arm bushings in the control arm s 2 Replace the upper or lower control arm s into the bulkhead 3 Reference the front suspension illustration for the appropriate fastener torque NOTE There is a washer located on the rearward lower control arm mounting at the bolt head WINNIN
165. rn the outer race of each bearing The bearings should turn smoothly and quietly The inner race of each bearing should fit tightly on the crankshaft The outer race should be firm with minimal side to side movement and no detectable up and down movement Replace any loose or rough bearings 5 5 and Coolinq Systems Connecting Rod Lower Bearing Measure connecting big end side clearance with a feeler gauge on both sides of the connecting rod The side clearance on either side of the connecting rod cannot exceed the connecting rod side clearance specification The difference between the two clearance measurements cannot exceed the maximum clearance differential specification Connecting Rod Side Clearance 012 016 30 40mm Maximum Clearance Differential 002 051mm Rotate the connecting rod on the crankshaft and feel for any rough spots Check radial end play in rod by supporting rod against one thrust washer and alternately applying up and down pressure Replace bearing pin and thrust washers if side clearance is excessive or if there is any up and down movement detectable in the big end bearing Piston Needle Bearing 1 Clean the end of the connecting rod and inspect inner bore with a magnifying glass Look for any surface 5 6 irregularities including pitting wear dents 2 Runa fingernail around the inside of the rod and check for rough spots galling or wear 3 and i
166. rocedures contained within whether whole or in part is expressly prohibited Printed in U S A UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual important information is brought to your attention by the following symbols A WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator bystander or person s inspecting or servicing the vehicle CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage NOTE NOTE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TORQUE provides a key for a required torque value TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL Loctite Registered Trademark of the Loctite Corporation Nyogel Trademark of Wm F Nye Co Fluke I Trademark of John Registered Trademark of Enterprises Inc Torx Registered Trademark of Textron M 10 Registered Trademark of FAST Inc WD 40 Registered Trademark of WD 40 Company Reaction Driven Clutch Registered Trademark of Team Industries Inc VM and TM Carburetors Registered Trademarks of Mikuni America
167. rocess I 2 5 18 remove pistons follow process for removing cylinder head and cylinders from engine To remove the crankshaft follow the process for disassembling the crankcase assembly With the piston out of the cylinder remove one of the c clips and discard Never re use piston c clips Push the piston pin out of the piston and upper rod bearings Inspect the pin for galling and abnormal wear Inspect the needle bearing by feel and replace as required New pistons are supplied with new rings and a piston pin It is recommended that new needle bearings be installed as well When installing a new piston insert one c clip into the piston making sure the open end is 180 opposite of the groove opening Apply a liberal amount of Polaris two stroke engine oil to the needle bearings piston pin and piston assembly Push the pin in to the piston then through the needle bearing Install the remaining c clip with the open end is 180 opposite of the groove opening PISTON RINGS BEARING NOTE Always use new cylinder base gaskets 9 10 Apply a liberal amount of Polaris two stroke oil to the cylinder wall Align the piston ring gaps around the piston locating pins Compress the upper ring then carefully slide the cylinder down over the ring Compress the lower ring then slide the cylinder down over the ring PERFORMANCE C POLARIS Engine and Cooling
168. s Strike the shaft at point A with a brass hammer To correct a situation like the one shown in this Squeeze the crankshaft at point A You will use the tool from the alignment kit PN 2870569 5 8 SUPPORT CRANKSHAFT AT THESE TWO BEARINGS HIGH 002 05mm 005 18mm PERFORMANCE gt POLARIS Engine and Cooling Systems Truing Examples HIGH 002 05mm If the crank rod pin location is 180 from the dial indicator opposite of above it will be necessary to spread the crankshaft at the A position as shown in illustration 3 When rebuilding and straightening a crankshaft A HIGH 005 13mm straightness is of utmost importance Runout must be as close to zero as possible WINNING PERFORMANCE gt POLARIS 5 9 Engine and Cooling Systems RECOIL ASSEMBLY Rope Removal and Installation TAB ENGAGES INSIDE PULLEY RECOIL SPRING FRICTION PLATE RATCHET SPRING TAB ENGAGES INSIDE HOUSING CAUTION Recoil spring under high tension Always wear eye protection when working with recoil housing components 1 With the recoil housing removed from the engine un tie any knots handle in the recoil rope and allow the pulley to slowly unwind 2 Remove the nut friction plate friction spring ratchet and ratchet spring from the pulley 3 the pulley straight out of the housing making sure spring is no lon
169. s inward it closes a small opening called a compensating port C within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the pistons D located in the brake caliper move toward the disc and applies pressure to the moveable brake pads As the lever pressure is increased the braking effect is increased The friction applied to the brake pads will cause the pads to wear As pads wear the piston within the caliper self adjusts and moves further outward Brake fluid level is critical to proper system operation A low fluid level allows air to enter the system causing the brakes to feel spongy Compensating Port Located within the master cylinder is a small compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the brake lever is released and the piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion caused by heat or contraction caused by cooling During system service be sure this port is open Due to the high temperatures created within the system during heavy braking it is very 7 10 important that the master cylinder reservoir have adequate space to allow for the brake fluid to expand Master cylinder reservoirs should be filled to the top of the fluid level mark on the inside of the reservoir 1 4 5 16 6 8 cm below lip of reservoir openi
170. sible to escape as you install the piston Screw tool PN PS 45908 into the Hold or place the reservoir as low as possible so the air will travel upward as you slowly cycle the IFP up and down Be sure to bottom out the piston in the reservoir body e Allow time for the bubbles to dissipate Repeat the process until all the air has been removed Set the IFP so it is approximately 1 8 from the bottom of the reservoir Install the bleed screw 9 11 20 Install the cap making sure the o ring does not flip over Install the snap ring 21 Charge the shock to the specified pressure 22 Clean the shock of all oil reside and check for any leaks 23 Install button screw onto the reservoir cap 13 With the cylinder head assembly pushed down against the valve piston dip the piston assembly in shock oil 14 Fill the shock body with oil to the bottom of the threads Carefully insert the piston rod and valve assembly into the cylinder Slightly oscillate the piston rod to allow the piston to enter the shock body bore as it purges the air out Slight up and down movement may be required to allow all the air to pass through the piston assembly 15 Slowly push the piston rod and assembly into the shock body until the threads can be engaged NOTE During installation some shock oil will over flow Wrap a shop cloths around the shock body to catch any oil overflow IMPORTANT
171. so that the spindles are off the floor 3 7 62cm 2 Insertthe alignment bar through both ski bolt holes in each spindles 3 Adjust Toe until handlebar is centered Toe Adjustment Toe is adjusted with the shocks and skis installed Track alignment must be correct before starting this process Toe alignment is measured at ride height 1 Liftfront of the machine off the floor rock the front end up and down and then set it down gently This will set the unit at ride height 2 Measure and make a mark 10 2 54cm forward of the ski mount bolt and 10 2 54cm behind the ski mount bolt preferably on the center line of the carbide skags 3 Place a straight edge along the one side of the track Make sure that the straight edge is touching along the length of the track 4 Recordthe measurements from the edge of the straight edge to the forward ski mark and the rearward ski mark 5 Adjust the tie rod so that both measurements are the same Place the straight edge on the opposite side of the track and measure the opposite ski marks 7 Adjust the tie rod so that both measurements are the same 8 Verify that the ski center distances are within specification from the forward marks and the rearward marks 8 10 DISASSEMBLY AND ASSEMBLY Spindle Removal Securely support the front of the machine up off the floor Remove the ski s Remove the upper control arm UCA to spindle fastener poma Remove the fastener secu
172. sure is to change the length of the front limiter straps Lengthening the straps decreases ski pressure under acceleration Shortening the straps increases ski pressure under acceleration Set up Recommendations for Optimum Performance Switchback Rear Suspensions DEEP POWDER SNOW Limiter strap in LOW position for maximum lift and flotation POWDER HARDPACK Limiter strap in STANDARD position for overall handling and speed over snow HARDPACK Limiter strap in HIGH position for increased control and less transfer 8 16 Torsion Spring Adjustment To adjust the rear torsion spring rotate the adjuster cam to the desired adjustment The cam has three sides LOW MEDIUM and HIGH Cam in LOW Position RAIL SLIDERS Wear Limit Replace sliders when wear exceeds notch If sliders look wavy in appearance check and adjust track tension or consider adding more bogie wheels Removal 1 Remove the rear suspension NOTE Some models may allow the rail sliders to be removed by sliding it through track windows with the suspension mounted in the machine 2 Remove front rail slider retaining bolt located at the rail tip 3 Use a block of wood or a drift punch and hammer to drive the slider rearward off the slide rail 4 With the rail slider at room temperature install a new rail slider by reversing steps 1 3 NOTE Lightly coat rail slider track clip area with a lubricant such
173. tch compression tool PN 8700220 4 Compress the clutch in the compression tool then secure the chain 5 Evenly remove the cover fasteners The cover bushing may be damaged if the cover is side loaded or mis aligned 6 Carefully remove the tension from the compression tool 7 Remove the cover and inspect the cover bushing Replace if damaged or worn NOTE Replace the cover bushing if the inside diameter is over 1 40 28 95mm 8 Remove the spring 9 Mount the drive clutch securely in a drive clutch holding gt POLARIS WASHER ROLLER PIN C SPACERS m i MOVEABLE SHEAVE CLUTCH SPACER WEIGHT WEIGHT PIN BEARING SLEEVE MOVEABLE INSERT STATIONARY SHEAVE fixture PN 2871358 10 Remove the Jam nut In a counterclockwise direction standard thread using the drive clutch spider nut socket PN 2871358 11 Install the spider removal tool PN 2870341 and remove the spider counterclockwise direction standard thread 12 Measure the total thickness of the spacer washers that are Installed on top of the clutch spacer Record the thickness of these spacer washers 13 Inspect both sheave surfaces for wear or damage 14 Inspect the moveable sheave bushing for wear or damage 15 Remove all three drive clutch weights 16 Inspect each weight The surface should be smooth with no waves or galli
174. that holds on the cowling on the LH side 9 Remove the Torx screws that hold the oil coolant bottles to the bracket 10 Move the RH cowling away from the footrest 11 Apply the parking brake 12 Tip machine over on its LH side 13 Remove the chaincase cover and clean it 14 Remove the lower gear 15 Remove the cotter pin on the jackshaft 16 Remove the castle nut and washer on the jackshaft upper sprocket 17 Release the parking brake 18 Release the tension on the chaincase tensioner 19 Remove the sprockets and chain from the chaincase 20 Remove the brake caliper bolts 2 Push the coolant hose enough to remove the caliper out of the way of the chaincase 22 Remove the rear suspension 23 Carefully slide the driveshaft down so that it clears the chaincase and remove the driveshaft 24 Remove the track from the chassis 25 Remove the chaincase retaining bolts 26 Slide the chaincase out of the chassis 27 Inspect the o ring and seal sleeve on the jackshaft and replace the o ring 28 Service the chaincase Chaincase Installation 1 Install the seal sleeve and o ring onto jackshaft The seal sleeve goes on first then the o ring 2 Install jackshaft installation tool PN 2871296 onto the jackshaft This will prevent damage to the seal 7 6 3 Install assembled chaincase onto the jackshaft in chassis 4 Insert carriage bolts through the back side of the chassis and install the Nylo
175. the stator plate to correct the timing After adjusting the recommended RPM timing continue with operating RPM timing if poor performance exists Continue on with left column Check the ignition switch throttle safety switches kill switch and harness for damage which can cause intermittent shorting problems Correct the problem Replace the module with the correct part and readjust the ignition timing Check the wiring connecting the coils and or replace the coils as necessary 11 11 ELECTRICAL SYSTEMS NOTES 11 12 NING PERFORMANCE Numerics 2008 Publication Part Numbers 2 4 600 RR Fuel Tank Assembly 4 13 7 92 Chaincase Assembly View 7 5 B Belt Burning Diagnosis 6 11 Belt Inspection 6 10 Belt Installation TEAM driven clutch 6 12 Belt Removal Team Driven Clutch 6 12 Brake Caliper Assembly 7 13 Brake Caliper Replacement 7 13 Brake Disc Replacement 7 13 Brake Fluid Indicator 3 9 Brake Fluid Inspection 3 9 3 9 Brake Hose 7 13 Brake Lever Travel Inspection 3 9 Brake Pad Replacement 7 13 Brake System Ble
176. the upper ring then carefully slide the cylinder down over the ring Compress the lower ring then slide the cylinder down over the ring PERFORMANCE gt POLARIS Engine and Cooling Systems 600 RR Crankcase INTAKE BOOTS REED STUFFERS REED ASSEMBLIES 22 IMPULSE FITTING CYLINDER STUDS OIL INJECTION CHECK VALVES WATERPUMP BUSHING SCREW 9 Ft Lbs 12 Nm B M8 22 Ft Lbs 30 Nm Apply Loctite 242 M6 9 Ft Lbs 12 Nm Apply Loctite 242 Disassembly Assembly Process 1 Remove engine from engine compartment Follow the process for removing the cylinder head cylinders pistons flywheel recoil housing and the water oil pump Remove the intake boots reed stuffers and reed assemblies from the intake tracks Discard any seals or gaskets Remove the fasteners from the bottom of the crankcase Carefully pry apart the crankcase halves Discard the PTO and MAG crankshaft seals WINNING PERFORMANCE gt POLARIS B C Remove the crankshaft Inspect as required Thoroughly clean the two crankcase mating surfaces with carburetor cleaner and a gasket remover Flush out the crankcase galleries Reinstall the crankshaft back into the lower crankcase using two new crankcase seals Apply a thin bead of Three Bond 1215 to the lower crankcase mating surface Install the upper crankcase Loosely install the crankcase fasteners then torque
177. thread showing above the plastic nut or the spring coils will stack resulting in damage To determine if the suspension is using full travel place the shock s jounce bumper against the shock body then test ride the machine The bumper will move on the rod in relation to the amount of travel For example if the shock travel is full the bumper will travel the entire length of the shock rod To prevent excessive bottoming out install the next highest rate spring or reduce the preload on the existing spring and change the shock valving to obtain the desired effect NOTE Shock valving can only be adjusted or changed on models that have serviceable shocks WINNING FERFORMAHCE gt POLARIS Alignment Bar Specifications DIAMETER 623 625 15 824 15 875mm LENGTH 45 114 3cm e MATERIAL C 1018 Rod Ends Rod ends must be parallel to their respective mounting surface after tightening jam nut If possible support the edge of the rod end to keep it from rotating out of position until jam nut is tight When rod ends are properly tightened the rod should rotate freely approximately 1 8 turn Rod End Engagement Rod ends must engage the rod a minimum of 2x the thread diameter when adjustment is complete Example 4375 11mm rod end A X 2 minimum thread engagement B 875 22mm 8 9 Steering and Suspensions Handlebar Centering 1 Raise the front of the machine off the floor
178. ting into reverse 4000 RPM Max RPM for operating in reverse 6000 RPM Engine must first reach 900 RPM at start up before the reverse system can be used The system works between 900 and 4000 RPM If the button is pushed above 4000 RPM the system is bypassed and nothing will happen Flashing light on the instrument panel indicates that the system is in reverse On carbureted units a slow flash indicates that the system 15 set for low elevation and a fast flash indicates the system is set up for high elevation Push and hold the reverse button for longer than 5 seconds to toggle back and forth from high and low elevation settings On Cleanfire units this is automatically done through the engine controller unit ECU Elevation above 6000 ft 1829m requires a different timing curve to eliminate a kick back effect When servicing clutches ensure that the vehicle is in the forward gear POLARIS ELECTRICAL SYSTEMS TROUBLESHOOTING TABLES No Ignition Spark Disconnect the single BLACK to BLK WHT wire from the CDI Module to the ignition kill circuit Does engine have spark Insert multimeter probes into the 2 pin Red and Brown ignition regulator rectifier harness Pull over engine Is DC voltage present Disconnect the stator to CDI module wires Test the resistance values of the stator coils as per the wiring diagrams Are the res
179. to remove from the head Old IHV 17 1 Desired 15 801 1 299cc s Removed cc s 1 299cc s I Stroke 6 0cm Displacement 199 098 x 2 54 I 0 01186 inches To find out how much to machine off multiply the number of cc s you need to remove by the number of inches to remove per 2 6 Thickness to remove I 0 01186 x 1 299 0 015 Port Opening Duration Port open 81 5 This indicates the degrees after TDC that the exhaust port opens and also the degrees before TDC that the port closes Duration closed 2 x 81 5 port open Duration closed 163 Total Duration 360 Duration Open Total Duration 360 Duration Closed 163 360 163 197 Duration Open 197 Percent Open Duration Open 197 Total Duration 360 x 100 197 360 0 54722 100 54 722 Percent Open 54 722 H IN G P E H FORMANCE POLARIS General Information TORQUE CONVERSION Ft Lb Nm US to Metric EL NDS MEL s a 1234 9 1302 _ Nm 82 4248 97 15 99 1261 98 1929 94 1275 99 1342 1288 135 6 WINNING CE POLARIS 2 7 General Information GENERAL REFERENCE Standard Bolt Torque Specification Q Grade 2 Grade 5 Grade 8 LL LL LL FT LB X 1 356 z N M N M 7376 FT LB Fuel Oil Premix Ratios 4 B BoLT SIZE EN 99 CO E E 20
180. ts to suit rider preference The machine should be methodically tested under the same conditions after each adjustment trail and snow conditions vehicle speed riding position etc until a satisfactory ride is achieved Adjustments should be made to one area at a time in order to properly evaluate the change Rear Suspension Ride Height 1 To set up the rear suspension torsion spring preload measure the distance between the ground and rear bumper with out the rider on the seat and the suspension at full extension This can be achieved by lifting the rear of the machine so that the suspension is off the ground and carefully setting the machine down Write this down as measurement X 2 Have the rider in full gear drop down on the seat work the suspension slightly by bouncing up and down and sit in the seated riding position With the rider in the seated position measure from the ground to the bumper in the same spot as you did for measurement X and write it down as measurement Y 3 determine the correct ride height subtract measurement X from measurement Y X Y ride height 4 The ideal ride height is Racer RR 4 5 10 13 5 Adjust for the desired ride height by rotating the torsion spring cams located on the rear of the torsion spring If the rear suspension ride height cannot be adjusted to the correct dimension optional torsion springs may be required This is only an initial setup
181. ug s Check for foreign material in carburetors Make sure no water or ice is present in the fuel tank lines or carburetors Poor running engine Bog Miss Backfire etc Use caution when loading machine Carbide skags may gouge into trailer and prevent drive train from spinning Loading machine on trailer freely Use enough speed to drive completely onto trailer If machine cannot be driven completely onto trailer it may need to be pulled or pushed to avoid belt wear burning Check for correct clutch components or damage on the Clutch malfunction PU p g Slow easy belt engagement easing on the throttle Use fast effective throttle to engage the clutch C POLARIS 6 11 PVT System Drive Belt Removal Team Driven Clutch NOTE Turn the key to the OFF position and allow the engine to come to a complete stop 1 Verify the driven clutch is not in reverse Open the clutch guard CAUTION Damage to the driven clutch or L wrench will occur when attempting to open the driven clutch when the driven clutch is in the reverse position 2 Insert the L wrench PN 2874857 A into the threaded hole B located on the driven clutch and turn it clockwise until the clutch sheaves are in the open position C 3 Remove the drive belt Drive Belt Installation Team Driven Clutch 1 With the L wrench inserted into the threaded into hole and the sheaves in the open position install the drive belt
182. uld line up when the clutch is assembled CAUTION Do not use impact wrench to remove or install the Drive Clutch Removal clutch bolt or clutch puller Damage to the clutch and or crankshaft can occur NOTE clutch tools can be found at the beginning of this chapter 1 Remove the belt 2 Place clutch holding tool 9314177 on the drive clutch 3 Remove the drive clutch retaining bolt Note the placement and number of washers on retaining bolt Insert the correct clutch puller into the retaining bolt hole 5 Tighten the puller into the clutch If the clutch does not come off strike the clutch puller head with a hammer If the clutch does not pop off continue to tighten the clutch 6 14 WINNING PERFORMANCE POLARIS PVT System Drive Clutch Disassembly ROLLER WASHER SPIDER BUTTON SPIDER COVER BEARING RETAINER CAUTION Wear eye protection when servicing the drive clutch Sheaves must be marked to provide a reference point for dutch balance and spider indexing If the sheaves are not marked and the spider washers are changed or misplaced the clutch may be out of balance and dam age to the clutch may result A WARNING Clutch spring is under extreme tension use caution when disassembling the clutch 1 Ina straight line mark the sheaves and the cover with a black marker or etched with a scribe Remove the clutch 3 Place the drive clutch in the clu
183. ust Systems VES 11 9 Vehicle Identification Number VIN 2 4 os rs chink E demit 2 4 W Walker Evans Air Shock Maintenance 9 9 Walker Evans Remote Reservoir Shock Maintenance 9 10 Wiring Diagram 2008 IQ 600 Racer 12 4 2008 IQ 600 RR Chassis 1 of 2 12 1 2008 IQ 600 RR Chassis 2 of 2 12 2 2008 IQ 600 RR Hood 12 3 IX 3 iagrams D iring W 600 RR Chassis Harness 1 of 2 2008 WIRES ARE REPRESENTED BY SOLID OR DASHED LINES TO SIMPLIFY TRACING IN DIAGRAM WIRE COLOR LEGEND ENGINE GROUND CHASSIS GROUND SWITCH NORMALLY CLOSED SWITCH NORMALLY OPEN TWO WIRE COLORS ARE SHOWN PS 296005 WITH MAIN TRACE COLORS ane EXAMPLE RD YE RED WITH YELLOW TRACE HEATER INDICATOR LAMP IN SWITCH 041 BN 012 BK 013 BK _042 BN s HANDWARMER SPLICE gt 5 8 lt i i Bo L 0 P2 P3 012 BK P4 PS 040 BN IGNITION SWITCH N BK START ON WH RD OFF al BRAKE LIGHT SWITCH LOCATED AT BRAKE LEVER BRAKE APPLIED NC ACTIVE NC NO ENGINE SHUT OFF SWITCH m SWITCH IS CLOSED UE IN NORMAL OPERATION TH GROUND SPLICE 2 AUXILIARY Tm 2 SHUT OFF 025 06 26 06 46 YE 45 YE 21 06 44 BN BN BN 35 BN 34 BN 0 B
184. wall Service life of the pistons and rings will be greatly reduced WINNING PERFORMANCE C POLARIS 7 Bend the pointer move the degree wheel until the pointer aligns with a 180 mark on the degree wheel 8 With the pointer aligned make sure the degree wheel and pointer are secured and will not move out of position Re check accuracy of this location a few times The pointer should align with the 180 mark when the dial indicator reads 100 2 54mm ATDC NOTE Do not move the crankshaft degree wheel or pointer after the initial setting on the MAG end cylinder simply read the wheel and dial indicator 9 Remove the dial indicator and install in PTO cylinder Repeat finding TDC process Note the degree wheel indication when the dial indicator reads 100 ATDC It should be 180 2 from the MAG cylinder mark 100 ATDC NOTE A Nicasil cylinder can be lightly honed with a soft stone hone but an not be oversized EXAMPLE OF A CROSS HATCH PATTERN 9 7 Engine and Cooling Systems Honing Procedure 1 Wash the cylinder with cleaning solvent Clamp the cylinder in a soft jawed vise by the cylinder studs 3 Place hone in cylinder and tighten stone adjusting knob until stone contacts the cylinder walls DO NOT OVERTIGHTEN Cylinders may be wet or dry honed depending on the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore Using
185. ward Operation 1 If unit was operated in reverse ensure that the path ahead is clear and push an hold the reverse button for 1 second and then release the button The engine will now automatically change direction form reverse to forward and the reverse light on the instrument panel will stop flashing 11 10 NOTE When servicing clutches ensure that the vehicle is in forward gear If not damage to the driven clutch may occur when removing the belt Altitude Setting If your engine is carbureted you can adjust the elevation setting of the Polaris electric reverse control PERC If your engine is a Cleanfire system this is automatically done through the engine controller unit ECU and you do not need to do any setting At higher elevations over 6000 ft 1829m the engine requires a different ignition RPM setting to improve the operation of the reverse system To set the altitude settings 1 With the engine running push and hold the reverse button for 5 6 seconds and then release the button The reverse light will flash rapidly on the instrument panel 3 Youhave now set the PERC system to the higher elevation setting 4 go back to the low elevation setting repeat step 1 The reverse light will flash slowly indicating that the system is now in the lower elevation setting NOTE The elevation setting will be set in the memory engine running or not until it is changed Important Notes Max RPM for shif
186. wheel Rotation 4 Connect an accurate tachometer and a good quality timing light to the engine according to manufacturer s instructions 5 If equipped turn the timing curve selector knob to D Start engine and increase RPM to the point specified the timing specifications Hold the throttle to maintain specified timing RPM Point the timing light at the timing inspection hole With your head positioned so there is a straight line between your eye the stationary pointer and the crankshaft center line note the relative position between the marked fly wheel line and the pointer If the stationary pointer is aligned with the mark made in Step 3 or within the acceptable variance ignition timing is correct 9 Ifthe pointer is outside the variance the stator will have to be rotated either with crankshaft rotation to retard the timing or against rotation to advance it NOTE Rotate stator plate approximately the same distance as the marks must move In most cases the recoil starter housing recoil drive hub and flywheel must be removed to loosen the stator bolts and change the timing On some engines the stator plate retaining screws can be accessed through the flywheel 10 Torque stator plate screws and flywheel nut to specified torque Apply Loctite 262 red to crankshaft flywheel taper if required Refer to the Specifications section for torque specifications and flywheel installation procedure for engine type
187. will act as an abrasive and cause damage to precision parts Clean the snowmobile before beginning service Clean new parts before installing CAUTION Watch for sharp edges which can cause personal injury particularly in the area of the tunnel Protect hands with gloves when working with sharp components CAUTION If difficulty is encountered in removing or installing a component look to see if a cause for the difficulty can be found If itis necessary to tap the part into place use a soft face hammer and tap lightly CAUTION Some of the fasteners in the snowmobile were installed with locking agents Use of impact drivers or wrenches will help avoid damage to fasteners CAUTION Always follow torque specifications as outlined throughout this manual Incorrect torquing may lead to serious machine damage or as in the case of steering components can result in injury or death for the rider s WINNING P E H FORMANCE POLARIS General Information CAUTION If a torquing sequence is indicated for nuts bolts or screws Start all fasteners in their holes and hand tighten Then following the method and sequence indicated in this manual tighten evenly to the specified torque value When removing nuts bolts or screws from a part with several fasteners loosen them all about 1 4 turn before removing them CAUTION If the condition of any gasket or O Ring is in question replace
188. ws from the helix then carefully pry the helix out of the moveable sheave 2 Install the clutch in the clutch compressor fixture PN 8700220 Install the extensions PN PS 45909 3 Wearing eye protection carefully compress the roller assembly to gain access to the snap ring Remove the snap ring 4 Slowly release the fixture arm to remove the roller assembly and spring Disassembly the clutch sheaves 5 Inspect the sheaves for abnormal wear Clean sheave faces with a Scotch Brite pad and a solution of warm soapy water 6 Inspect spring spring cup spacer and rollers for wear and replace as required 7 To assemble the clutch slide the components back on to the stationary sheave shaft 8 Align the notch in the roller assembly with row of double splines on the shaft Slowly compress the spring and roller assembly down on to the shaft Install the snap ring making sure it is fully seated in the groove 9 Install the helix by aligning the rollers with the ramps Push the helix down into the sheave while keeping the screws holes aligned 6 20 M Drive and Systems CHAPTER 7 Drive and Brake Systems GEAR RATIO SPEED CHART xe gu ease 7 2 CHAINGASE SPEED CHARTS 488888 aga 7 2 GEARS DRIVE 7 4 DRIVE CEAR Gat tere xu dad eae ee LEA 7 4 BRIVE to o Dass lupo

2008 600 RR / IQ RACER SNOWMOBILE SERVICE MANUAL

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