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Polaris 600 IQ Offroad Vehicle User Manual

1. Engine S4772 6044 OR6N Displacement 599 cc Cylinders 2 Bore x Stroke mm 77 25 x 64 Alternator Output 400 watt Throttle Body Mikuni Throttle Body Bore Size 46 mm Idle RPM 1700 200 Cooling Liquid Ignition Type Digital Ignition Timing 18 1700 RPM 120 F 49 C water temp Spark Plug Gap NGK BPR9ES 028 in 0 70 mm Fuel Octane 9 Recommended 87 Minimum Electric Fuel Gauge Standard Electric Start Standard Low Oil Light Standard Parking Brake Standard Speedometer Standard Tachometer Standard 114 SPECIFICATIONS Clutching Chart ALTITUDE Drive Clutch Drive Clutch Driven Clutch Driven Chaincase Meters Shift Weight Spring Spring Helix Gearing Feet Pitch Shaded cells indicate factory settings 0 600 11 64 Dark 140 200 P2 Tab 40 38 45 P2N 19 41 0 2000 1322604 Blue White 7043495 D13I 157 Borg Warner 7041781 66P 600 1200 10 62 Dark 140 200 P2 Tab 40 38 45 P2N 19 41 2000 4000 1321586 Blue White 7043495 5137157 Borg Warner 7041781 66P 1200 1800 10 60 Dark 140 200 P2 Tab 40 38 45 P2N 19 41 4000 6000 1321587 Blue White 7043495 5137157 Borg Warner 7041781 66P 1800 2400 10 58 Dark 140 200 P2 Tab 40 38 45 P2N 19 41 6000 8000 1321588 Blue White 7043495 5137157 Borg Warner 7041781 66P 2400 3000 10 56 Dark 140 200 P2 Tab 40 38 45 P2N 19 41 8000 10000 1321684 Blue White 7043495 51371
2. 12 SAFETY Operator Safety Rider Capacity Your snowmobile is designed for up to two riders A decal on the console indicates that the vehicle is designed for one operator and one passenger only WARNING Operating improperly with a passenger could cause loss of control and result in serious injury or death Control becomes more difficult with two people on board More space is required to make turns and longer distances are needed for stopping Make sure the passenger remains seated behind the driver facing forward with both feet placed firmly on the running boards Slow down and avoid jumping the snowmobile Snowmobiles designed for two riders should never be operated with more than two people on board Slow down Control becomes more dif ficult with two people on board More space is required to make turns and longer distances are necessary for stopping 13 SAFETY Operator Safety Cargo Capacity See page 32 for cargo loading information WARNING Overloading the cargo carrier can cause loss of control resulting in severe injury or death The maximum cargo carrier capacity is 75 Ibs 34 kg Never exceed the cargo carrier capacity Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills WARNING Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Do not allow disabled perso
3. Move the adjuster to the left to lower the beam Move the adjuster to the right to raise the beam 30 FEATURES Shifter Shifter For normal operation place the transmission in high gear When ever towing or operating with a heavy load place the transmission in low gear See page 73 When operating in low gear vehicle speed will be limited to protect the drive train Glove Box The glove box is a heated dry stor age area intended for drying wet gloves Do not use the glove box for items that could be damaged by heat Glove Box Latch Turn the knob to release the glove box cover latch and open the cover Seat Latch Release the seat latch and raise the seat to access the battery and under seat storage area Check the seat latch before each use of the snowmobile Push downward on the seat near the seat latch then attempt to raise the seat by pulling upward on the right hand passenger grab handle Make Seat Latch sure the latch is secure before riding Under Seat Storage When using the under seat storage area to transport supplies and other items pack the items securely to prevent them from moving around in the storage area Smaller items should be placed in bags or containers to keep them secure Storage Area 31 FEATURES 12 Volt DC Outlet Use the 12 volt DC outlet to power a global positioning sensor GPS heated helmet shield utility light cell phone or other accessories The
4. Check the auxiliary shut off switch for proper operation Push the switch down to stop the engine Pull it up to allow restarting Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operating Mirror Adjustment If equipped adjust your mirrors so they can be used to their full advan tage Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile 61 OPERATION Fuel Safety A WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel outdoors or in a well ventilated area Always turn off the engine before refueling Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time A WARNING The engine exhaust from this product contains chemicals known to cause can cer birth defects or other reproductive har
5. Loosen the 7 16 inch jam nut Using a 1 8 inch Allen wrench aturn the set screw inward clock wise to increase the distance between the sheaves or outward counterclockwise to decrease the distance Tighten the jam nut Remove the L wrench and store it in the tool kit 97 MAINTENANCE Clutch System Drive Belt Removal NOTICE Do not attempt to remove the drive belt after operating in reverse The snowmobile must be stopped after forward motion to prevent damage to components during belt removal Rotate the driven clutch counterclockwise 1 4 turn by hand to ensure forward engagement before attempting to remove the belt Stop the engine after operating in a forward motion 2 Turn the ignition key off Wait for the engine to come to a complete stop 3 Lock the parking brake 4 Open the hood and remove the left side panel 5 Rotate the driven clutch counterclockwise 1 4 turn by hand to ensure forward engagement 6 Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves open far enough to remove the belt If the wrench does not turn readily rotate the driven clutch counterclockwise an additional 1 4 turn by hand and try again 8 Grasp the belt at the lower edge and remove it 98 MAINTENANCE Clutch System Drive Belt Installation 1 DA gv RN Drop the drive belt over the drive clutch and pul
6. Add DOT 4 brake fluid only Do not overfill See page 116 for the part numbers of POLARIS products 90 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action Bleed the system before operating the snowmobile WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Never operate the vehicle with a spongy feeling brake lever During the bleeding procedure keep the brake handle as level as possi ble The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent 1 Remove brake master cylinder reservoir cover and gasket 2 Fillthe master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 6 8 cm below the lip of the reservoir open ing Reinstall the gasket and cover 3 Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and release the brake lever 6 Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles WARNING Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock resulting in serious injury or death
7. Any unauthorized modifications to clutches such as adding or removing weights will void the warranty NOTICE The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum perfor mance Please see your POLARIS dealer if you experience a decrease in performance 95 MAINTENANCE Clutch System Drive Belt Condition Periodically check the condition and tension of the drive belt and always carry a spare Inspect the belt for signs of excessive wear frayed edges missing cogs cracks and excessive looseness Replace the belt if any of these conditions exist See Drive Belt Troubleshooting on page 121 For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile Drive Belt Deflection Straight Measure belt deflection with both Measure Edge clutches at rest and in their full neutral position Place a straight edge on the belt and apply downward pressure while measuring at point A This measurement should be 1 1 4 3 2 cm 96 MAINTENANCE Clutch System Drive Belt Adjustment 1 Install the L wrench into the open threaded hole in the outer sheave of the clutch see page 98 Turn the wrench clockwise slightly to remove pressure from the sheaves
8. If any of the decals depicted in this manual differ from the decals on your snowmobile always read and follow the instructions of the decals on the snowmobile If any decal becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety decals are pro vided by POLARIS at no charge The part number is printed on the decal Clutch Warning This warning decal is found under the hood on the air plenum WARNING Do not operate with hood open Do not attempt adjustment with engine running Do not operate engine with plenum belt guard removed Never run engine with drive belt removed Never service clutches yourself See your dealer Pressure Cap Warning This warning decal is found under the hood on the pressure cap of appli cable liquid cooled models WARNING Do not open hot Test or replace when changing coolant Press down and turn to release cap 13 PSI 24 SAFETY Safety Decals and Locations Passenger Warning Snowmobiles designed for an operator and one passenger have a warn ing decal on the console For more information on operating with a pas senger see page 13 WARNING This vehicle is designed for operator and ONE passenger only Track Warning WARNING Stay clear of track Do not sit on seat back Entanglement with the track or a fall from seat back may result in severe injury or death 25 SAFETY Safety Decals and Locations Reverse Warning
9. Replace worn or damaged fuel lines promptly NOTICE Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it promptly 84 MAINTENANCE Cil Lines Inspect oil line condition every 1000 miles 1600 km Cil Filter The oil filter is located at the side of the oil tank Have your dealer change the oil filter and bleed the system annually or every 1000 miles 1600 km Have your dealer inspect the return check valve as well Tip The direction of the arrows indicates the direction of flow through the filter Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 76 CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running 1 Allow the engine and exhaust system to cool completely 2 Open the hood 3 Inspect the muffler and pipes for cracks or damage Check for weak or missing retaining springs or damper support grommets 4 Replace any damaged or missing components 5 Clean the plastic surfaces next to the muffler with aerosol Carbure tor and Throttle Body Cleaner See page 116 for the part numbers of POLARIS products 6 Close the hood 85 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60
10. ant temperature becomes too hot for safe continued operation of the engine If you must drive your machine after the high temperature indi cator light has come on drive slowly and stop frequently to allow the engine to cool down Driving in deep snow will also help cool the engine See your dealer for service Add coolant if the level is low Engine performance will be reduced if you continue operating when the high temperature light is on Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine the system should be completely drained every two years and a fresh mix ture of antifreeze and distilled water should be added Have your POLARIS dealer perform this service 87 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION Steam and hot liquids will cause burns to your skin Never bleed the cooling system or remove the pressure cap when the engine is warm or hot Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part NOTICE If coolant flow becomes restricted or plugged coolant loss air lock or engine damage may result Most cooling systems are equipped with a filter that should be periodically inspected or replaced Perform the bleeding procedure when the engine is cold 1 88 Position the vehicle so that the top of the tunnel is level Elevate the
11. 40 mixture of ethylene glycol and distilled water This mixture provides protection against freezing Contact your dealer if greater protection is required Use POLARIS Antifreeze 60 40 Premix POLARIS Antifreeze is already premixed and ready to use Do not dilute with water Never exceed a 60 antifreeze 40 water mixture See page 116 for the part numbers of POLARIS products Tip Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system Use of a non standard pressure cap will not allow the recovery system to function properly If the pressure cap needs replacement contact your dealer for the correct part CAUTION Steam and hot liquids will cause burns to your skin Never remove the pressure cap when the engine is warm or hot Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are Coolant recovery bottle Coolant reservoir Pressure cap Connecting hoses Always maintain the coolant level at the COLD FILL mark on the coolant recovery bottle when the engine is cold NOTICE Operating the snowmobile with insufficient coolant will result in overheating and serious engine damage Always maintain the coolant level as recommended 86 MAINTENANCE Cooling System Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine cool
12. 95 99 Clutch Warning 24 Clutches e emn 20 Clutching iere ttes 115 Coolants ecse nr tinsen 86 Coolant High Temperature Light 87 Coolant L yel s se ros eene 86 Cooling System 86 88 Cooling System Bleeding 88 Cooling System Flushing 87 Coupler Lubrication 80 134 D DC Outlet 12 Volt 32 DET 1 52 thor eee tH 34 Detonation Elimination Technology 34 Digital Display suus 35 Disabled Operators 14 Drive Belt 225 evo b RR 20 Drive Belt Adjustment 97 Drive Belt Break In 65 Drive Belt Condition 96 Drive Belt Deflection 96 Drive Belt Installation 99 Drive Belt Removal 98 Driver Awareness 0 16 Driving Downhill 18 Driving in Hilly Terrain 19 Driving on Slippery Surfaces 19 Driving Responsibly 22 E Electrical System 94 Emission Control Information 74 Emission Control Label 74 Emission Control Maintenance 74 Emissions Limited Warranty 129 130 Engine Break In 64 65 Engine Restarting 67 Engine Stop Switch 70 Environment Preservation 6 Exhaust System esses 85 Eye Protection 0 80000 12 F Fuel Filter e aeae pd ers 84 Puel Eines J reo antes 84 Fuel Premix Initial F
13. Always add brake fluid to the fill line as recommended 7 After bleeding is complete refill the reservoir to the proper level See page 57 8 Reinstall the gasket and cover 91 MAINTENANCE Lights Removing Halogen Bulbs Tip Do not touch a halogen bulb with bare fingers Oil from skin leaves a resi due causing a hot spot that will shorten the life of the lamp If fingers do touch the bulb clean it with an alcohol moistened towel 1 Remove the plenum cov ering from the headlight Bulb assembly Lift the rubber boot to expose the bulb Spring 2 Push down on the spring to release it from the housing 3 With the wire harness attached to the bulb withdraw the bulb from the housing 4 Grasp the bulb by its metal base and carefully separate the bulb from the harness Harness e 92 MAINTENANCE Lights Installing Halogen Bulbs 1 2 3 4 o 6 Hold the bulb by its metal base and install it into the wire harness Insert the bulb into the housing Connect the spring to the housing Carefully flip the spring back into the housing placing it around the wire harness Reinstall the plenum covering on the headlight assembly Adjust headlight aim See page 30 Replacing Taillight Bulbs 1 Qv Qn ZB th Remove the screws securing the taillight cover and remove the COVer Remove the taillight lens Push the bulb in and twist it counterclockwise to remove it Install the new bulb Reinstal
14. MN 55340 provides a ONE YEAR LIMITED WARRANTY on all components of the POLARIS snowmobile against defects in material or workmanship Warranty period will vary regionally This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty The warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a POLARIS dealer Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your snowmobile is very important in ensuring trouble free operation Purchasing a snowmobile in the crate or without proper dealer set up will void your warranty coverage Warranty Coverage and Exclusions Limitations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and te
15. Operation Warning Reverse Warning POLARIS snowmobiles equipped with standard reverse and will have this decal on the console 26 WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual SAFETY Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all POLARIS snowmobiles WARNING To avoid serious injury or death read and understand all warnings and the Owner s Manual before operation If manual is missing con tact a POLARIS dealer for a replacement This vehicle is capable of high speeds Buried objects or uneven terrain can cause loss of control Reduce speed and use extreme caution when operating in unfamiliar terrain Excessive speed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes to avoid unexpected obstacles or to stop safely Never consume alcohol or drugs before or while operating this vehi cle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and ade
16. be denied Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination The following items are excluded from warranty con sideration if the failure was due to wear or not the direct result of a defect Skis Ski wear rods Tracks Slide rails Suspension components Finished and unfinished surfaces Brake components Carburetor Throttle body components Seat components Engine components Clutches and components Drive belts Steering components Hydraulic components Batteries Circuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper compone
17. both switches OFF squeeze and hold the throttle in the wide open position Crank the engine several times to clear the engine Release the throttle Restart the engine using the normal starting procedure Stopping the Snowmobile The following chart lists methods for stopping the snowmobile See page 70 for more information about the engine stop switch THROTTLE SYSTEM WHAT IT DOES CONDITION Ignition Switch Interrupts ignition circuit All Brake Slows jackshaft All Engine Stop Switch Interrupts ignition circuit All 67 OPERATION Cil Low Oil Indicator Light The low oil indicator light may flicker at times due to oil movement in the bottle but when the light comes on and remains on add the recom mended oil before further operation Visually check the oil level in the bottle The engine may be operated as long as oil is visible in the oil tank If oil is not visible continued opera tion may cause serious engine damage Low Oil Level Maintaining the proper oil level will prevent system aeration and possi ble loss of pumping action which could result in engine damage This is especially important when the machine is operated in mountainous ter rain Always check the oil level when refueling When the oil reaches the low level mark add one quart 9 liters of recommended oil to the tank See page 64 for oil recommendations NOTICE Operating the snowmobile without adequate engine lubrication
18. but always operate within safety limits and on 2 up machines with respect for a passenger If the snowmobile is carrying a load and is equipped with a high low transmission drive in low gear the first several feet then stop and shift to high gear Maneuverability While much control and maneuverability is achieved through the steer ing system and skis maximum control is achieved by the shifting of your body weight Maneuverability will change for lighter operators or snowmobiles designed to carry a load or a passenger 20 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is a requirement for operation of your snowmobile NOTICE Driving in too little snow will result in excessive wear and damage to the slide rail track and or engine WARNING Inadequate cooling and lubrication will lead to overheating of the slide rail and track causing premature wear damage and failure which can result in serious injury Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating for prolonged periods on ice hard packed surfaces or roads Operating in Deep Snow If the snowmobile becomes stuck in snow clear the running board area of snow then step down the snow in front of the snowmobile so that when the
19. cannot be reset ENG F Engine Temperature x A thermometer measures water temperature giving an indication of engine temperature Air Temperature if equipped The MFD displays actual air temperature in either standard or metric units Enter the Engine Program 2 Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement 41 FEATURES Instrumentation MFD Digital Display Programs Engine Program Altitude if equipped The rider can calibrate the altimeter for current atmospheric conditions Altimeter accuracy will be 300 ft 91 m after adjustment 1 Enter the Engine Program Tip Press and hold the MODE switch for ten sec onds to switch between standard and metric units of measurement When ALt displays the program is in the metric mode 2 Press and release the SET button until the altimeter screen is active 3 Press and hold the SET button for five seconds When the digits begin to flash release the button 4 Press and release the SET button once to advance 50 feet 15 m Tip Press and hold the SET button to advance quickly by 100 foot 30 m incre ments 5 Adjustthe altitude display to within 50 ft 15 m of current altitude Tip The gauge reads barometric pressure and allows the rider to compensate for daily fluctuations in air pressure The gauge can adjust the displayed altitude to 1300 ft 396 m from the preset va
20. deep snow Use fast aggressive throttle to engage clutch Riding with high RPM Lower the gear ratio Reduce RPM Avoid riding in high ambient temperatures Check for snow ingestion Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Poor engine performance Check for fouled plugs or water ice or dirt in the gas tank or fuel line Loading machines onto trailers Skis may gouge into trailers and prevent the drivetrain from spinning properly Use enough speed to drive the machine completely onto the trailer Push and pull it to finish loading if necessary Clutch malfunction Inspect clutch components See your dealer Slow easy clutch engagement Use fast aggressive throttle to engage clutch Wrong or missing belt Always use the recommended belt Improper break in Always break in a new belt and or clutch by avoiding aggressive or high speed operation during the break in period 121 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty information contained in this manual Contact your POLARIS dealer for replacement parts service or warranty Your dealer receives frequent updates on changes modifications and tips on snowmobile ma
21. first tank of fuel as outlined below Oil added to the fuel and oil injection systems will provide the necessary engine lubrication Oil Recommendations First Tank of Fuel POLARIS Premium Blue 2 Cycle Oil After Break in POLARIS VES 2 Cycle Oil Tip The Premium Blue oil will seat the rings faster than the VES oil See page 116 for the part numbers of POLARIS products Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage Oils may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All POLARIS oils are compatible with each other Initial Fuel Premix Always premix fuel in 5 gallon 19 liter increments in a separate fuel container Never add oil directly to the fuel tank Fuel Premium Blue Oil Ratio Each 5 gal 19 I 16 oz 473 ml 40 1 64 OPERATION Break In Period Engine Break In Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle openings and vehicle speeds to reduce friction on all close fit ting machined parts allowing them to break in slowly without damage NOTICE Use of any lubricants other than those recommended by POLARIS may cause serious engine damage We reco
22. front of the vehicle slightly if necessary Place the transmission in neutral Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark Remove the bleed screw from the water outlet manifold and or the thermostat housing Allow the coolant to bleed through the system until it runs out the bleed holes Reinstall the bleed screw into the manifold Add coolant to the coolant bottle to the maximum mark Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air Stop the engine and check the coolant bottle level Fill as required Feel the heat exchangers under the tunnel If the system is bled properly they ll be warm to the touch If they re not repeat step 6 Lift the front of the machine slightly to assist in the bleeding Replace the pressure cap and carefully lower the front end of the machine MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile See page 57 Brake pads must be replaced when the brake pad material becomes thin ner than the backing plate approximately 1 16 1 5 mm A kit is avail able for replacing brake pads See your dealer WARNING Brake failure during operation can result in serious injury or death Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the
23. outlet is located on the console near the ignition switch Cargo Carrier Whenever towing or operating with a heavy load place the transmission in low gear See page 73 WARNING Overloading or towing improperly can alter vehicle handling and can cause loss of control Do not exceed the cargo carrier capacity Always reduce speed and allow greater distance for braking and turning when carrying cargo or a passenger or when towing Always secure cargo before operating vehicle Overloading or carrying tall off center or unsecured loads will increase your risk of losing con trol Loads should be centered carried as low as possible and firmly secured to the carrier Becareful if load extends over the side of the carrier The maximum weight capacity for the cargo carrier is 75 Ibs 34 1 kg Do not allow a passenger to sit on the seat back or in the cargo carrier Cargo Carrier NOTICE Do not drive aggressively or jump your vehicle when operating with heavy loads in the cargo carrier This may cause vehicle damage 32 FEATURES Fuel Resistor This snowmobile is equipped with a feature that allows the engine con troller to select the proper operating software based on the type of fuel being used See pages 62 63 for fuel information and recommendations Make sure the correct resistor is installed for your fuel choice as instructed below PREMIUM NON ETHANOL Resistor To achieve maximum performan
24. sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage 56 PRE RIDE INSPECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine Brake Lever Travel Squeeze the brake lever It should move no closer to the handgrip than 1 2 1 3 cm A smaller distance indicates low brake fluid level or air in the hydraulic system See pages 89 91 or see your dealer for service 1 2 1 3 cm Brake Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Check for the presence of air in the fluid system See pages 89 91 or see your dealer for service WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always have the brakes serviced at the first sign of sponginess Brake Fluid Check the brake fluid in the mas Master Sight ter cylinder before each ride Cylinder Glass View the brake fluid level through the sight glass on the top of the master cylinder The eye will appear dark when the fluid level is full If the sight glass is any color other than black add brake fluid See page 90 57 PRE RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever l
25. throttle is opened the snowmobile will be able to climb up and over the snow 21 SAFETY O perator Safety Driving Responsibly Every snowmobile handles differently and even the most docile condi tions may become dangerous if operators drive improperly If you re new to snowmobiling acquaint yourself with the machine and with what it will and won t do under various conditions Even seasoned driv ers should spend some time getting the feel for a machine before attempting ambitious maneuvers 22 A snowmobile depends on the rider s body position for proper bal ance in executing turns traversing hills etc Always start on a smooth level area to begin building your operating experience Before allowing someone else to use your snowmobile know the extent of their operating skills Check to see if they ve taken a snow mobile safety course and have an operator s certificate For their pro tection as well as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide pro tection under normal riding conditions Your snowmobile is not intended for this kind of use Be courteous to oncoming traffic by dimming your headlights and reducing yo
26. track studs to maintain proper vehicle control while turning on hard packed snow or ice Check skags before each use of the snowmobile to ensure positive steer ing characteristics Skags must be replaced when worn to half their orig inal diameter Tip Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement Raise and support the front of the snowmo bile so the skis are approximately 6 inches 15 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse the steps to install a skag 107 MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Release the seat latch and raise the seat to access the battery 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable last 4 Remove the battery Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can dam age the battery and result in a shorter life It can also hinder vehicle per formance Follow the bat
27. you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 1500 mi 2400 km 131 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS KM 132 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 133 INDEX A Accessories prenosa ee esses 53 Air Pollution rere 6 Apparel 15e e S tette ca 12 Avalanches 4 17 B Backrest oes t aches bs e 30 Battery eese 108 110 Charging 2c cer nu 109 110 Installation L 108 Removal 108 SOTALC EN wed 109 Brake Components 89 Brake Fluid 5 405 etch bac ees 57 90 Brake Inspection 89 Brake Lever Feel 6 06 0 ees 57 Brake Lever Travel 57 Brake System Bleeding 9 Brakes 2 229 xs waves 57 89 91 Break In Period 64 65 Bulbs Replacing 92 C Cargo Capacity 14 Cargo Cartier esee 32 Cargo Overload 14 Cargo Rack Lus 30 32 Cleaning for Matte Finishes 111 Clutch Alignment Offset 95 Clutch System 0
28. 57 Borg Warner 7041781 66P 3000 3600 10 54 Dark 140 200 P2 Tab 40 38 45 P2N 19 41 10000 12000 1321685 Blue White 7043495 5137157 Borg Warner 7041781 66P 115 POLARIS PRODUCTS Part No Description Engine Lubricants 2870791 Fogging Oil 12 oz Aerosol 2875035 Premium Blue 2 Cycle Oil qt 95 I break in only 2875036 Premium Blue 2 Cycle Oil gal 3 8 I break in only 2877882 VES 2 Cycle Oil qt 95 I 2877953 VES 2 Cycle Engine Oil 2 qt 1 9 I 2877883 VES 2 Cycle Engine Oil gal 3 8 I 2877884 VES 2 Cycle Engine Oil 2 5 gal 9 5 I Chaincase Lubricants 2873105 SCL Synthetic Chaincase Lubricant qt 95 I 2873106 SCL Synthetic Chaincase Lubricant gal 3 8 I Grease Specialized Lubricants 2871312 Grease Gun Kit All Season 3 0z 89 ml 2871322 All Season Grease 3 0z 89 ml cartridge 2871423 All Season Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 I 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 I Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT4 Brake Fluid 2872893 Engine Degreaser 2870505 Isopropyl Fuel De Icer 2872889 Brake and Clutch Cleaner 2872890 Carburetor and Throttle Body Cleaner 116 Engine Troubleshooting Unless you have experience and training in two cycle engin
29. 600 10 Widetrak Snowmobile Owner s Manual for Maintenance and Safety A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polaris com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products e Snowmobiles All terrain vehicles ATVs Low emission vehicles LEVs e RANGERQ utility vehicles VICTORY motorcycles GEMQ vehicles We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever pro duced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information
30. 9 26 33 85 28 21 14 7 10 7 14 21 27 34 40 27 20 13 6 1 8 15 22 29 36 45 26 19 2 5 2 9 16 23 80 37 50 26 19 12 4 8 10 17 24 81 38 55 25 18 1 4 3 11 18 25 32 39 60 25 17 10 3 4 t1 19 26 83 40 Frostbite in 3 30 min 10 min WIND CHILL CHART C Wind Actual Thermometer Reading C Speed 5 2 a 4 7 0 13 16 19 22 25 28 31 34 37 40 43 46 Km h Equivalent Temperature C Cam 5 2 1 4 7 0 48 6 19 22 8 3 o 4 7 a1 14 18 l 22 l 25 29 16 2 2 6 10 13 47 21 24 28 32 24 1 3 7 1 15 19 22 26 30 34 32 0 4 8 12 16 20 24 28 32 36 40 1 5 9 13 17 21 25 29 88 37 48 1 5 9 13 18 22 26 30 34 38 56 2 6 10 14 48 22 26 31 85 39 64 2 6 10 15 19 23 27 31 85 40 72 2 7 41 45 19 23 28 32 36 40 80 3 7 t1 15 20 24 28 83 87 41 88 3 7 12 16 20 24 29 33 87 42 96 3 8 12 16 21 25 29 34 88 42 Frostbite in gt gt 30 min 10 min 23 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protec tion Read and follow the instructions of the decals and other warnings on the snowmobile carefully
31. ATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting if equipped Enter the Performance Program l Hel 1 Press and release the SET button until the clock screen is active RPM f 3 Press and hold the SET button for five seconds i 2 58 E 4 When the hour starts flashing press the SET switch once to advance one hour Press and hold the SET button to advance the hours quickly 5 Press and release the MODE button to save the hour The minutes will begin flashing 6 Setthe minutes in the same manner 7 When finished press and release the MODE button to save the new setting If the MODE button is not pressed within ten seconds the gauge will automatically save the new entry 40 FEATURES Instrumentation MFD Digital Display Programs Engine Program Press and release the MODE button until the engine program screen is active The default display for this screen includes engine hours electri cal system voltage level fuel level if equipped and either engine cool ant temperature air temperature accessory or altimeter accessory Press and release the SET button to cycle through the following screens hour meter engine temperature air temperature available as an acces sory altimeter available as an accessory and turbo boost if equipped Hour Meter The hour meter records the total hours of engine operation since manufacture This meter
32. Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system This condition may lead to a sudden loss of brakes and or fire and may result in serious injury or death 18 SAFETY Operator Safety Driving on Slippery Surfaces WARNING Never attempt an abrupt change of direction when operating on slippery surfaces Proceed slowly and use extra caution Driving on ice or hard packed snow reduces steering and braking control which may result in loss of control and serious injury or death Slow down and use extra caution when operating on slippery surfaces Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and snowmobile rollover causing serious injury or death Use caution and good judgement when driving in hilly terrain Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible rollover Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the other side of the hill If you re unable to continue up a hill turn the snowmobile downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling back dow
33. Plugged fuel filter or SEE YOUR DEALER tank pick up sock Incorrect clutching SEE YOUR DEALER Engine continually Faulty plug s Change plug s Fuel System Dirt or ice may be in the fuel system deicer should be added to non ethanol fuel at all times for assurance against fuel line icing more than normal pulls to start Incorrect throttle SEE YOUR DEALER freeplay or faulty switch Engine requires Poor fuel Replace with fresh winter fuel Not enough fuel SEE YOUR DEALER getting to engine Plugged fuel filter or e SEE YOUR DEALER tank pick up sock 119 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension Set static sag see page 48 Adjust torsion spring blocks or bottoms too easily install optional torsion springs to achieve correct sag dimensions Rides too stiff in rear Check for binding suspension components and grease all pivot points Set static sag see page 48 Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions Too much weight Set static sag see page 48 Adjust torsion spring blocks or transfer when install optional torsion springs to achieve correct sag climbing Move limiter strap to high position see page 50 Too little weight Set static sag see page 48 Adjust torsion spring blocks or transfer when install optional torsion springs to achieve correct sag c
34. RIS product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind other than safety bulletins Vehicles reg istered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic war ranty For questions call POLARIS Customer Assistance see page 122 128 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited war ranty for your vehicle POLARIS Industries Inc warrants that at the time it is first pur chased this emissions certified vehicle is designed built and equipped so it conforms with applicable U S Environmental Protection Agency emission regulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on
35. about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period POLARIS POLARIS and IQ are registered trademarks of POLARIS Industries Inc Copyright 2013 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the original instructions Printed in U S A 2014 600 IQ Widetrak Owner s Manual P N 9924294 TABLE OF CONTENTS Introduction i ak ERROR RR 5 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recor
36. ack A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil or rich fuel mixture 83 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system When operating in loose powder snow check the foam filters periodically to remove any accumulation of snow NOTICE Operating the snowmobile with the intake filters removed may cause intake icing The result will be poor fuel economy or intake malfunction Always reinstall the intake filters before operating the snowmobile Intake Filter Fuel Pump All fuel pump service must be performed by an authorized POLARIS dealer Do not attempt to service the fuel pump Fuel Filter Fuel Lines See your POLARIS dealer for replacement of the fuel filter at the inter vals outlined in the Periodic Maintenance Table beginning on page 76 Contaminated or poor quality fuel will shorten the life of the fuel filter and result in poor engine performance Always store fuel in clean fuel containers If low fuel pressure or reduced engine performance occurs between the recommended fuel filter service intervals the filter may need replacement See your dealer Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after periods of storage Normal dete rioration from weather and fuel compounds may occur
37. al Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding clubs When teaching inexperienced operators to ride set up a predetermined course for practice Make sure they know how to drive and control the snowmobile before allowing them to make longer trips Teach them proper snowmobile courtesy and enroll them in driver s training and safety courses sponsored by local or state organizations INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education cam paign We encourage state and provincial governments across the snow belt to adopt rigorous safety training programs that encourage protection of our environment including wildlife and vegetation Snowmobile clubs and other organizations are working together to pro tect our environment Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment Noise Level One of the most publicized issues about snowmobiles is noise The Society of Automotive Engineers SAE the standard setting body for snowmobile development recommends that snowmobiles co
38. ally if the transmission is in reverse Never engage the starter when the engine is running 2 Pullthe engine stop switch up to the RUN position 3 Turn the key to START to crank the engine Release the key to the ON position when the engine starts If using the starter rope grasp the starter handle and pull slowly until the recoil engages then pull abruptly to crank the engine TIP Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Damage may result 4 Ifthe engine does not start after several attempts slightly depress the throttle no more than 1 4 inch 6 mm open while cranking the engine When the engine starts immediately release the throttle CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running NOTICE Operating the vehicle immediately after cold starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle If cold drive away is attempted the engine RPM may stumble slightly to protect the engine 66 OPERATION Restarting an Engine If the rider stops the engine by pushing the engine stop switch down restart the engine using the normal starting procedure If the engine fails to start using the normal procedure 1 2 3 4 5 6 Push the engine stop switch down to the OFF position Turn the key to the OFF position With
39. and component life continue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to service or make adjust ments to your snowmobile If you re not familiar with safe service or adjustment procedures and the use of tools or if you don t feel comfort able performing these tasks yourself contact an authorized POLARIS dealer for service NOTICE Hot components can cause damage to plastic Always make sure the exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection 75 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions You may need to increase frequency based on riding conditions When inspection reveals the need for replacement parts always use genuine POLARIS parts available from your POLARIS dealer Item See Frequency Page iso mi so0mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CLUTCH Clutch Alignment Offset 95 l I l w
40. ar abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for pur poses other than for which it was manufactured The warranty does not cover any dam ages that occur during trailer transit or as a result of unauthorized service or parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the snowmobile due to fire explosions or any other cause beyond POLARIS control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the snowmobile The exclusive remedy for breach of this warranty shall be at POLARIS exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARIS ING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CON SEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE Some states do not permit the e
41. brake pad material becomes thinner than the backing plate approximately 1 16 1 5mm Brake Components _ Gears Backing Brake Caliper Brake Disc Plate Gearcase Brake Disc Backing Plate Brake Pad Material Replace when thickness is less than 1 16 1 5 mm Brake Pad Brake Material Caliper 89 MAINTENANCE Brakes Brake Fluid A WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury Keep the master cylinder cover free of dirt and debris The vent slits allow for diaphragm movement and if they become plugged movement of brake fluid below the diaphragm may be restricted altering brake function NOTICE Brake fluid will damage decals paint and some plastics Always wipe up spills immediately Check the brake fluid in the mas Master Sight ter cylinder before each ride Cylinder Glass View the brake fluid level through the sight glass on the top of the master cylinder The eye will appear dark when the fluid level is full If the sight glass is any color other than black add brake fluid 1 Position the handlebars so the master cylinder is level 2 Remove the master cylinder cover 3
42. can result in serious engine damage Always check the oil level when refu eling Add oil as needed The POLARIS oil cap on the oil bottle is vented to allow proper oil flow See your POLARIS dealer for recommended replacement parts Always maintain the oil level between the add mark and the bottle neck Do not fill the bottle neck See page 64 for oil recommendations Add Mark 1 Immediately stop the engine if the uL F low oil indicator light comes on 2 Open the left side panel 3 View the oil level in the oil bottle 4 Add oil as needed before operating NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refu eling Add oil as needed 68 OPERATION Track Warm Up A WARNING A loose track or flying debris could cause serious injury or death Stand clear of the front of the snowmobile and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throttle dur ing warm up or when the track is free hanging Be sure the rear support is sta ble 4 WARNING Use of traction products such as studs ice growsers etc will increase the possi bility of track damage and or failure This could cause loss of control resulting in serious injury or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up of the engi
43. cause temporary spark plug fouling due to the preser vative added during the assembly process Avoid prolonged idle speeds which cause plug fouling and carbonization NOTICE Using non recommended spark plugs can result in serious engine damage A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug Always use the spark plugs recommended for your snowmobile Use recommended spark plugs with the proper gap Refer to the spec ifications section beginning on page 114 e Use only resistor type spark plugs Torque spark plugs to 18 20 ft Ibs 24 27 Nm Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds If a plug is fouled replace the plug with a new plug CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 82 MAINTENANCE Spark Plugs Normal Spark Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service Tip The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjust ments Wet Fouled Spark Plug The wet fouled insulator tip is bl
44. ce install this resistor to the ECU fuel designation connector when using Non ethanol gasoline with a 91 octane rating 10 ETHANOL Resistor This resistor must be installed when using Ethanol gasoline Other forms of oxygenated gasoline MTBE gasoline Any fuel less than 91 octane Whenever in doubt of your fuel purchase use the 10 ETHANOL resistor as a safeguard The resistor is installed into the wiring harness on the left side of the snowmobile just above the top of the oil bottle To change resistors unplug the resistor and rotate it to align and install the appropriate plug to the connection NOTICE Engine damage may occur if ethanol fuel is used while the non etha nol fuel resistor is installed The check engine light may also display in this condition as this could cause detonation ETHANOL MTBE OR OTHER OXYGENATED GASOLINE Factory Delivery ANY FUEL WITH ETHANOL or LESS THAN 91 OCTANE 87 Octane Minimum 10 ETHANOL Resistor Installed NON ETHANOL GASOLINE 91 OCTANE Maximum Performance 33 FEATURES Detonation Elimination Technology DET The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active When excessive detonation is detected the check engine light will illuminate flicker or flash momentarily Check Engine Light Status Indicates Solid or Flickering De
45. ck 58 Passenger Warning 25 Polaris Products 116 Pre Ride Checklist 54 Pressure Cap Warning 24 R Rail Slide Wear 104 Relay Label essaiar hons tne 94 REVEISC cscs is eee esee EY EY 72 Reverse Warning 26 Rider Capacity 13 S Sately ouis tes bes Lac e 8 23 Safety Decals suus 24 27 Seat Latch secs e 31 55 Seat StOLAGS ereti aia eremi 31 Shifter ecese ra ensia eude m canes 31 Shock Compression Valving 51 Shock Spring Preload Front 46 KASS es ce acne eas hay Nal ERG 107 Ski Alignment 106 Ski Pressure 2 ecce eas 50 Snow Build up 18 Snow Conditions 21 Spark Plugs 82 83 135 INDEX S Specifications 114 115 Speed i i sg bacc tsee erred 15 Spring Preload IQ 48 Starting the Engine 66 Starting the Engine Restarting 67 Steering Inspection 105 Steering System 56 105 107 Stop Switch 2 5 c0 4 sagsaesvases 70 Stopping the Engine 67 Stopping the Snowmobile 67 Storage Daily 2 0 06 ccs cee es 73 Storage Extended 111 113 Storage Under Seat 31 Survival Preparation 11 Suspension Adjustments Front 46 Suspension Adjustments Rear 47 51 Suspension Coupling IQ 51 Suspension Inspec
46. cted by your dealer Test the throttle safety switch system daily before operation Stop Switch 1 Sit on the seat 2 Start the engine and allow it to idle 3 Hold the throttle lever pin stationary by exerting pres sure on the pivot pin in the direction shown in the illustration 4 Apply a slight amount of throttle A properly functioning switch must shut down the engine 70 OPERATION Throttle Lever WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control which could result in serious injury or death If the throttle lever does not work properly DO NOT start the engine If the engine speed limits at 2400 RPM when the throttle lever is released 1 Turn the ignition switch to OFF 2 Visually inspect the throttle cable and throttle body to determine what caused the safety switch to activate 3 Test the throttle lever by compressing and releasing it several times The lever and cable must return to the idle position quickly and completely 4 Ifthe throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 Ifthe engine doesn t start take the snowmobile to an authorized POLARIS dealer for service 71 OPERATION Electronic Reverse PERC A WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occ
47. d the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measure ment Y from X sag X Y Adjust sag by rotating the torsion spring preload cams located on the rear torque arm See page 49 The ideal amount of sag for this rear suspension is 2 5 inches 6 4 cm X Y 2 5 in 6 4 cm lt lt gt With Rider No Rider 48 THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload rotate the three position cam using the engine spark plug tool This adjustment is easier to make if tension is relieved from the spring Exercise extreme caution if you use this method of adjustment and follow the steps below carefully WARNING A sudden release of tension from a spring could result in serious injury Wear eye protection and maintain a firm grip on the spring when removing and installing it 1 Grasp the spring firmly with both hands 2 Maintain a firm grip on the spring and carefully remove the long leg from the guide block Be prepared for a sudden release of tension 3 Carefully allow the leg to unwind and relieve tension from the cam 4 Rotate the cam to the desired setting 5 Rewind the long leg of the spring Maintain a firm grip on the spring while reinstalling it into the guide block Tip Different rate torsion springs may be available if a firmer ride is desired Contact y
48. ded in the owner s manual Safely 8 This section describes safe vehicle operation and identifies warning decals and their locations Features i ssz s RRAAREEEXAAEEAAEEERG 28 This section identifies the locations of your snowmobile s controls and features The Perfect Fit 46 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 54 This section explains procedures that must be performed before riding Operation issu RRRERAREERRRRRAe S 62 This section explains proper engine break in operation of features and general operating procedures Maintenance sernne 74 This section defines your role and your dealer s role in your snowmobile s regular maintenance Specifications Lee 114 POLARIS Products s RR e 116 Troubleshooting es 117 Warranty ss cccdtscee i cece sees EU ENEES 122 Maintenance Log 131 IndeX oueessesuiRR ERRARE REZERRREAEGUERE 134 INTRODUCTION Important Notes for Owners and Drivers After reading this manual store it in the snowmobile for convenient ref erence It should remain with the snowmobile when the snowmobile is sold Some of the illustrations and photos used in this manual are general rep resentations Your model may differ Follow the maintenance program outlined in this manu
49. e to the ski spindles not to the ski loops to prevent damage to the steering components Place the transmission in neutral and have someone ride on the towed snowmobile to operate the brake and steering when necessary NOTICE Towing a disabled snowmobile with the transmission in gear can result in serious damage to the engine and drive system Always place the transmission of the disabled snowmobile in neutral before towing T3 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain replace or repair the emission control devices or systems on your snowmobile Emission Control Label Your snowmobile is equipped at the time of sale with an emission control information ECI label and a factory installed emissions information hangtag These items are required by U S Environmental Protection Agency regulations The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover The ECI label should not be removed even after you purchase the snowmobile You may remove the factory installed emissions information hangtag which is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer
50. e under the same conditions trail and snow condi tions vehicle speed riding position etc after each adjustment until the best ride is achieved IFS Components 1 Skis 2 Front shocks and springs 3 Rod ends 4 A arms IFS Adjustment Options Front shock spring preload Optional springs Toe ski alignment see page 106 Camber see your dealer Front Shock Spring Preload The factory preload setting should be appropriate for most riders and conditions Please see your POLARIS dealer for assistance before attempting to adjust preload Increasing the spring preload too much may adversely affect the han dling of the snowmobile and the performance of the rear suspension Decreasing the spring preload too much may allow the lower spring retainer to fall off 46 THE PERFECT FIT Rear Suspension Adjustments Rider weight cargo weight riding style trail conditions and vehicle speed all affect suspension action Each rear suspension can be adjusted to suit rider preference and deliver the best performance for a given set of conditions However all suspen sion designs and adjustments involve a compromise or trade off For example a suspension set up for snow cross racing would provide a very stiff ride on the trail A suspension set up for trail riding would bot tom out harshly on a snow cross course Make adjustments to one area at a time so you can evaluate the change For further assistance please s
51. e button 4 Press the button again up to five times to advance the reminder in 50 hour increments Tip The maximum interval is 250 hours 5 Press and release the MODE button to save the new settings To disable the service interval reminder 1 Press the SET button once after reaching 250 hours on the display The gauge will display OFF Gauge Cleaning 1 Wipe the gauge face as needed using a clean cloth and a mild soap and water solution Wipe dry with clean soft cloth 2 Cleanthe back side of the gauge using a clean cloth and a mild soap and water solution Do not remove the electrical connectors or pro tective rubber boot Do not spray the back side of the gauge or the wire harness with a pressure washer or other water source NOTICE To prevent damage to the lens do not use alcohol for cleaning Do not allow chemicals or sprays to contact the lens Immediately clean off any gasoline that splashes on the gauge during refueling 45 THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension IFS Break in the suspension for approximately 150 miles 240 km before making any fine tuning adjustments Settings will vary from rider to rider depending on rider weight vehicle speed riding style and trail conditions We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference The snowmobile should be methodically tested one change at a tim
52. e lock nuts 12 Tighten the idler shaft bolts Torque to 35 ft lbs 47 5 Nm 103 MAINTENANCE Track Alignment Periodically check that the track is centered and running evenly on the slide rails Misalignment will cause excessive wear to the track and slide rail 1 Safely support the rear of the snowmobile with the track off the ground 2 Startthe engine and apply a small worm Avy amount of throttle until the track turns slowly at least five com plete revolutions Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track runs to the left loosen left locknut and tighten the left adjusting bolt If the track runs to the right loosen right locknut and tighten the right adjusting bolt 4 After adjustments are complete tighten locknuts and torque idler shaft bolts to 35 ft Ibs 47 5 Nm 5 Repeat steps 2 and 3 to verify proper alignment Rail Slide Wear For ease of inspection all POLARIS rail slides have a Minimum 3 wear limit indicator groove to Thickness indicate the minimum permissi ble slide thickness Replace the rail slides if they are worn to the top of the groove at any point Replace when along their length dem to top of NOTICE Failure to replace worn groove rail slides may result in permanent damage to the track or rails 104 MAINTENANCE Ste
53. e refer enced pages Item See Page Drive Belt Condition 96 Steering System 56 Brake Fluid 57 Brake Lever Parking Brake Lock 57 58 Brake System 89 Throttle Lever 55 Throttle Safety Switch 55 Auxiliary Shut Off Switch Engine Stop Switch 61 70 Ignition Switch 61 67 Taillight Brakelight Headlight 61 Coolant Level 86 Gearcase Oil Level 79 Injection Oil Level 68 Radiator Cooling Fins clean and remove any debris Suspension Mounting Bolts 60 Skags Wear Bars 60 107 Ski Saddle and Spindle Bolts 60 Hood Straps Latches 56 Seat Latches 55 Rear Wheel Idler Bolts 60 103 Track Alignment Condition 59 104 Rail Slide Condition 104 54 PRE RIDE INSPECTIONS Before Starting the Engine Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start the engine without checking all vehicle components to be sure of proper operation WARNING Operating the vehicle with worn damaged or malfunctioning components could result in serious injury or death Never start the engine without checking all vehicle components to be sure of proper operation Read and Understand Your Owner s Manual Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience Throttle Lever The throttle and brake are the primary controls of your snowmobile Always
54. e repair see your dealer if technical problems arise TROUBLESHOOTING Problem Probable Cause Solution Erratic engine oper ating RPM during acceleration or load Drive clutch binding e SEE YOUR DEALER Driven clutch e SEE YOUR DEALER of spec variations malfunction Harsh drive clutch Drive belt worn or e Replace the drive belt engagement too narrow Excessive belt e SEE YOUR DEALER sheave clearance Drive belt turns over Wrong belt for e Replace the drive belt application Clutch alignment out SEE YOUR DEALER Engine mount broken or loose Inspect and replace SEE YOUR DEALER Machine fails to move Clutch jammed Check for twisted belt or broken spring SEE YOUR DEALER Track jammed Foreign object may be caught or the rail slide melted to the track clips due to lack of lubrication Track may be iced up or frozen to the ground Chaincase sprocket or chain jammed or broken Chain is loose or broken or chain tightener is loose SEE YOUR DEALER Transmission is in neutral Place the transmission in gear 117 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch SEE YOUR DEALER system components Bearing failure SEE YOUR DEALER gearcase jackshaft or front drive shaft Drive belt surface nspect and replace as needed flat spots Drive chain loose nsp
55. e the transmission is in for ward 72 OPERATION Daily Storage At the end of each ride park the snowmobile on a level surface and sup port it at the rear with an appropriate track stand The track should be suspended approximately 4 10 cm off the ground Remove the key and cover the snowmobile Towing For your safety do not attempt to use a tow hitch until you ve read the following warnings and understand the proper hitch functions WARNING Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects resulting in serious injury or death DO NOT tow toboggans sleds saucers or any type of vehicle with a rope Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in the towed object Braking distances increase when towing loads Slow down to maintain control of the snowmobile Whenever towing or operating with a heavy load place the transmission in low gear Towing in high gear can result in belt damage When oper ating in low gear vehicle speed will be limited to protect the drive train If the snowmobile becomes Shifter inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rop
56. ect and adjust or replace Drive chain worn SEE YOUR DEALER sprocket teeth bro ken Poor low RPM Worn drive belt nspect and replace as needed performance Excessive belt sheave clearance SEE YOUR DEALER Sticky clutch SEE YOUR DEALER Poor fuel quality Use 87 89 octane fuel Engine doesn t turn Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fuel supply broken parts or improper cooling Hydrostatic lock Fuel may have entered the crankcase while the vehicle was standing or being transported SEE YOUR DEALER to correct the cause Drain plug s are located on the lower crankcase for emergency draining 118 Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails to start Faulty ignition TROUBLESHOOTING Install new spark plug s If engine still fails to start check for spark If there s no spark SEE YOUR DEALER No fuel to engine Make sure the fuel valve is on Make sure the fuel tank contains fuel Ice may be in the fuel line filter or pump Add isopropyl alcohol to the fuel system Poor engine This indicates a major engine backfires compression problem that must be repaired before operating SEE YOUR DEALER Engine lacks power Fouled or defective Replace the plug s spark plug s Fuel filter loss of SEE YOUR DEALER high RPM power
57. ee your POLARIS dealer Suspension Performance Tips Rider weight usually determines the position at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve very little time or effort and greatly affect the ride n deep snow a new rail slide will offer improved performance over a worn slide It can also improve top speed POLARIS offers track kits for improved flotation in deep snow See your dealer for assistance Tip Keep the suspension pivot points lubricated This will reduce moisture and rust build up and ensure proper function of the suspension components Grease rear suspension pivots before adjusting the rear suspension Refer to the suspension lubrication information beginning on page 80 47 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting Sag Method To set up the rear suspension torsion spring preload measure the dis tance between the ground and rear bumper This is measurement X Take the first measurement with no rider and with the rear suspension at full extension Tip The rear bumper may need to be raised slightly to fully extend the rear sus pension Next have the rider drop down hard on the seat and bounce up and down several times collapsing the rear suspension With the rider seated measure the distance between the ground an
58. ering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners 105 MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control resulting in serious injury or death Do not attempt to change the ski alignment or camber adjustment See your POLARIS dealer 1 Place the handlebars in a straight ahead position 2 With only vehicle weight compressing the suspension measure 10 inches 25 4 cm forward from the center of the ski mounting bolt See illustration At this point measure between the skis This is measurement X 3 Perform the same measurement rearward from the center of the ski mounting bolt This is measurement Y 4 The X measurement should be 1 8 1 4 inch 3 6 mm greater than the Y measurement If the skis are misaligned see your dealer for alignment correction as camber adjustment may also be affected 10 in 25 4 cm 10 in 25 4 cm 106 MAINTENANCE Steering System Ski Skags WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommended skags If you install longer or more aggressive carbide skags than the original equipment it may also be necessary to add
59. f you move or are traveling within the country where your vehicle was purchased War ranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If You Move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Vehicles importa tion rules vary considerably from country to country You may be required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS Industries in order to register your vehicle in your new country You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and notices regarding your vehicle 127 WARRANTY How to Get Service If Purchased From A Private Party If you purchase a POLA
60. for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is avail able to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owner s Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty and read the maintenance section of your owner s manual You are responsi ble for ensuring that the specified maintenance is performed POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 74 MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble free miles of snowmobiling enjoyment follow recommended regular maintenance and perform service checks as out lined in this manual Record maintenance and service in the Mainte nance Log beginning on page 131 The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles 240 km 500 miles 800 km and 1000 miles 1600 km These inspections should be per formed by a qualified service technician For continued optimum perfor mance
61. harge 0 25 11 5 volts or less Needs charge with At least 20 hours desulfating charger 110 MAINTENANCE Matte Clear Coat Cleaning if equipped Matte finish products are prone to trapping dirt oils and other contaminants POLARIS Industries recommends cleaning with warm water and a mild dish detergent Use a soft sponge to gently rub the surface and rinse with clean warm water For stubborn stains such as grease or oil use a citrus based cleaner 3M Citrus Base Cleaner recommended Spray onto the area to be cleaned and rub with a soft sponge Allow to sit for a couple of minutes and wash away with clean warm water Repeat as necessary to clean the surface NOTICE Never use a polishing buffing wax or any sponge that has an abrasive surface These products will buff the matte surface of the finish resulting in a glossy finish It is not recommended that you clean matte finishes with a pressure washer as this will further imbed contaminants into the clear coat and possibly damage the decals Extended Storage Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components See page 116 for the part numbers of POLARIS products Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any ru
62. ill 64 Fuel Pump iis eem mme 84 Fuel Recommendation 63 Fuel Resistor 000 33 Fuel Safety 2 ose ee 62 Fuel System Deicers 63 Fuse Label 2 o es 94 G Gauge Cleaning 45 Gearcase Oil Level 79 Glove BOR asradi eeuk eot teas 3l H Handlebar Adjustments 52 Headlight Adjusting 30 Helhiiet z ssssueet RR ERE ELTE 12 High Temperature Indicator Light 87 Hood Latches 56 l Ice and Snow Build up 18 TES Le raa apes Set pede toute 46 Instrumentation 35 45 Intake Filters 0 84 Intake Silencer 20 L Lamps Replacing 92 Light High Temperature Indicator 87 Lights 5k e Res 92 03 Limiter Strap Position 50 Low Oil Indicator Light 68 Lubrication 79 81 M Maintenance Interval Table 76 78 Maintenance Program 75 Maneuverability 20 Matte Finish Cleaning 111 MFD Components 35 MFD Digital Display Programs 38 45 MFD Settings 36 37 N INGIS c 6 O Oil Filter o e E ER 85 Oil Injection System 65 Cl Level seo hia PEE ERE 68 Qil Lies scarce eines 2 85 Oil Recommendations 64 Oil GeatCase zs sse ceases 79 Operating in Deep Snow 21 Operation Warning 27 P Parking Brake Lever Lo
63. intenance which may supersede information contained in this manual Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following information 1 Serial number 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experienced 6 Length of time and conditions of operation 7 Previous correspondence Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine POLARIS Customer Service United States 1 888 704 5290 Canada 1 204 925 7100 122 WARRANTY Service And Warranty Information POLARIS Anti Theft System The POLARIS anti theft system PATS monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines Administration 1 POLARIS snowmobile owner reports theft A In addition to notifying the proper law enforcement officials the owner must call POLARIS Customer Service B Owners must provide their name address telephone number and the model and serial number of stolen machines 2 POLARIS warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 POLARIS warranty will aid in notifying the proper owner when a unit is recovered 123 WARRANTY Limited Warranty POLARIS Sales Inc 2100 Highway 55 Medina
64. it the gas tank windshield or any other part of the machine when turned fully to the left or right If necessary loosen the set screws for the left and right controls rotate the controls slightly then tighten the set screws to the proper torque NOTICE Do not stretch wires while adjusting the controls Stretching the wires could damage the handwarmers Right control torque 35 in Ibs 3 95 Nm 10 Left control torque 24 in Ibs 2 7 Nm 10 6 Torque the front bolts first then torque the rear bolts Torque the bolts to 15 17 ft Ibs 20 23 Nm 7 Reinstall the handlebar cover Jn Adjuster Block Bolts 8 Reinstall the mountain bar 52 THE PERFECT FIT Accessories POLARIS offers a wide range of accessories for your snowmobile to help make each ride more enjoyable Use only POLARIS parts and accessories on your POLARIS snowmobile Use of unapproved parts and accessories may result in Non compliance with government industry requirements Voiding of warranty Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems Exhaust systems are critical safety areas that must use approved POLARIS parts Please see your POLARIS dealer for service 53 PRE RIDE INSPECTIONS Pre Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile Procedures are outlined on th
65. ith the engine running Track adjustment is critical for proper handling Always maintain cor rect tension and alignment TRACK TENSION DATA CHART Suspension Slack Measurement Weight Measurement Location Widetrak IQ 3 4 1 19 25 mm 10 Ibs 16 40 cm 4 54 kg ahead of rear idler shaft Tip Tip 102 Tension adjustments should be made only after the track is warmed up and limber Turn the engine off Lift the rear of the snowmo bile and safely support it off the ground Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel Measure at the point where the weight is hanging MAINTENANCE Track Tension 4 Check for specified slack between the wear surface of the track clip and the plastic rail slide Idler Sh Adjusting ay an Screw Lock Nut If the track needs adjustment 5 Loosen the rear idler shaft bolt 6 Loosen the lock nuts 7 Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the track 8 Repeat the measurement on the other side of the track Tip Check more frequently when the snowmobile is new 9 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 10 Check track alignment see page 104 and adjust as necessary 11 Tighten th
66. ithout belt Clutches 95 l I l l Drive Belt 96 C C C Belt Tension x l I l l Clutch Sheaves 97 l I l l ENGINE COOLING Engine Mounts l I l l Recoil Rope l l l l Cylinder Head Bolts l I l Cylinder Base Nuts l l I l Ignition Timing BTDC l I l VES System C C C l Coolant Level 86 l l R l Coolant Hose l l l l Coolant Circulation l l l Coolant Leaks l l l l Spark Plugs 82 I I I R I Exhaust Pipe 85 l l Exhaust Retaining 85 l I l l Springs Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 76 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page iso mi soo mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season BRAKES Hose Routing l l l l Hose Condition l l l l Fluid Leaks l l l l Brake Pads 89 l l l l Brake Disc l l l l Parking Brakes 58 l l l l Brake System 57 89 l Brake Fluid 57 l FUEL MANAGEMENT Idle RPM l l l Throttle Lever 55 71 l l l l l Oil Pump Lever l l l synchronize Throttle Cable 80 L L L Throttle Position Sensor l l l Fuel Lines 84 l l l l l Fuel Filter 84 EVERY 2000 3200 or EVERY 2 YEARS Oil Filter 85 R R Oil Lines l l l Air Box l l l l l ELECTRICAL Auxiliary Shut Off 61 l l l l l Switch Throttle Safety Switch 70 I l I l l Ignition Switch
67. l tank Follow the instructions on the conta

Polaris 600 IQ Offroad Vehicle User Manual

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