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Polaris 600 INDY Offroad Vehicle User Manual

1. 49 Grab Handle Adjustment 32 H Handlebar Adjustments 60 Headlight Adjusting 31 Helmet eren ty ane wee 12 High Temperature Indicator Light 97 Hood Latches eee 66 l Ice and Snow Build up 18 le Gavia e Eria 50 Instrumentation 36 49 Intake Filters isc pc pe tee eects 94 Intake Silencer 20 L Lamps Replacing 103 Light High Temperature Indicator 97 Lights 5 2 224 sabes E 103 Limiter Strap Position 56 Low Oil Indicator Light TI Lubricati ti 9 rn 88 89 M Maintenance Interval Table 85 87 Maintenance Program 84 Maneuverability 20 MED Battery Replacement 48 49 MFD Components 36 MED Digital Display Programs 39 47 MFD Settings 37 38 N INOISG 3 tia reete emi ce rcr 6 O Oil Filt r e ste IRI EIS 95 Oil Indicator Light 77 Oil Injection System 73 Oil Leyal ete poirir isk TI Oil Eines ore RUE ea I 95 Oil Recommendations 72 Operating in Deep Snow 21 Operation Warning 27 P Parking Brake Lever Lock 68 Passenger Warning 25 Polaris Products 120 Pre Ride Checklist 64 Pressure Cap Warning 24 R Rail Slide Wear 112 Rear Rear Scissor Stop 58 Rear To Front Coupling
2. 81 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 Do not use the front bumper to pull or drag the snowmobile The front bumper is not designed for this type of use and may detach from the vehicle if force is applied 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 If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damage to the steering components Re
3. NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter when the engine is running Engaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Make sure the area behind your snowmobile is clear 3 Push the yellow reverse button on the left hand control for one second then release Tip A reverse light on the instrument panel will indicate that the transmission is in reverse 4 Apply the throttle slowly to make sure the transmission is in reverse Tip If the engine stops running the transmission will be in forward gear when it s restarted Reverse Button 80 OPERATION Electronic Reverse PERC Disengaging Reverse 1 Stop the snowmobile and leave the engine idling 2 Push the yellow reverse button for one second and release The light on the instrument panel will shut off 3 Apply the throttle slowly to make sure the transmission is in for ward Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency See page 78 for more information about the engine stop switch SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch Interrupts ignition circuit Throttle Safety Switch Interrupts ignition circuit Tether Switch Option Interrupts ignition circuit
4. TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 1500 mi 2400 km 135 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS KM 136 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 137 INDEX A Access Panel Radiator 31 ACCESSOTIES ese ee ang eine rnc 61 Adjustable Steering System 33 34 Apparel zoo sp sprmasie ve meses 12 Avalanches lssslssesls 17 B B ckiestii ecce cre TS 30 Battery Replacement MFD 48 Belt Break In 73 Brake Components 100 Brake Fluid elseesess 101 Brake Inspection 100 Brake Lever Feel essseu 67 Brake Lever Travel 67 100 Brake System Bleeding 102 Brakes oe Res 67 100 102 Break In Period 72 73 Bulbs Replacing 103 C Cargo Bag 2 eve Ir eet 31 Cargo Overload 14 Cargo Rack sce dey cade eoe ne 30 Chaincase Oil Les 90 91 Clutch Alignment Offset 104 Clutch Cover Warning 24 Clutch System 104 107 Clutches ve RR pr rg Sy 20 Cl tchitig ene Re 119 Coolant DRE 96 Coolant High Temperature Light 97 Coolant Level
5. 29 16 2 2 6 30 13 47 21 24 28 32 24 1 8 7 11 15 19 22 26 30 34 32 o 4 8 12 16 20 24 28 32 86 40 31 5 9 13 17 21 25 29 88 37 48 31 5 9 43 18 22 26 30 34 88 56 2 6 10 14 18 22 26 31 35 39 64 2 6 10 15 19 23 27 31 35 40 72 2 7 M 15 19 23 28 32 36 40 80 3 7 11 15 20 24 28 33 37 M 88 3 7 12 16 20 24 29 33 37 42 96 3 8 12 46 21 25 29 34 38 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 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 Cover Warning This warning decal is found under the hood on the clutch cover 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 en
6. 5 Reinstall the spark plug cap 93 MAINTENANCE Intake Filters The intake foam filter limits snow ingestion into the intake system When operating in loose powder snow check the top of the foam filter periodically to remove any accumulation of snow Fuel Injectors All fuel injector service must be performed by an authorized POLARIS dealer Do not attempt to clean or service the fuel injectors Fuel Pump All fuel pump service must be performed by an authorized POLARIS dealer Do not attempt to service the fuel pump Fuel Filter See your POLARIS dealer for replacement of the fuel filter at the inter vals outlined in the Periodic Maintenance Table beginning on page 85 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 Fuel Lines 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 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 9
7. 600 IQ LAT 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 abou
8. 67 PRE RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary for example when parked on an incline for a period of five minutes or less 1 Brake Lever 2 Parking Brake Lever Lock 3 Master Cylinder Reservoir Cover 4 Fluid Level Indicator Lock Engagement To engage the lock squeeze the brake lever tightly and push forward on the lock Hold the lock forward while releasing the brake lever Tip If the brake lever is squeezed tightly enough the lock will move freely into place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightly The lock will return to the unlocked position WARNING If the parking brake lever lock is partially or entirely engaged while riding the brakes may overheat resulting in brake damage In extreme cases it could cause a fire which could result in serious injury or death Always ensure that the lever lock is completely disengaged before operating the snowmobile 68 PRE RIDE INSPECTIONS Before Starting the Engine Track Inspection
9. THE PERFECT FIT Handlebar Adjustments Use the RIDER SELECT feature to adjust handlebar position See page 33 Use the following steps to adjust handlebar angle at the handlebar block 1 Remove the handlebar cover to expose the handlebar and the four adjuster block bolts 2 Usinga 7 16 wrench loosen the four nuts on the bottom of the adjuster block turn han dlebar to left or right for access to back nuts Tip If necessary pry the blocks apart with a screwdriver 3 Adjust the handlebar to the desired height Be sure han dlebars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any Nuts other part of the machine when turned fully to the left or right If necessary loosen the set screws for the left and right con trols 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 4 Torque the front bolts first then torque the rear bolts Torque the bolts to 15 17 ft Ibs 20 23 Nm 5 Reinstall the handlebar cover 60 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 snowmo bile Use of una
10. WARNING Operating the snowmobile with a damaged track increases the possibility of track failure which could cause loss of control resulting in serious injury or death Always inspect the track for damage before using the vehicle WARNING Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty 69 PRE RIDE INSPECTIONS Before Starting the Engine Suspension Inspection Loose nuts and bolts can reduce your snowmobile s reliability and cause needless repairs and down time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the follow ing items on a weekly basis or before any long trip Item Check Page Suspension mounting bolts Tightness Rear idler wheel bolts Tightness 111 Rear idler adjusting bolt locknuts Tightness Torque arm bolts Tightness Carrier and bogie wheel bolts Tightness Front torque arm limiter strap Condition Rail slide Condition 112 Track Tension 110 All rear suspension components Lubrication 88 Ski
11. 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 If Purchased From A Private Party If you purchase a POLARIS product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage
12. 58 Recoil Rope luus 65 Reverse Operation 80 81 Reverse Warning 26 Rider Capacity s 4 eterne xe 13 RIDER SELECT 33 34 RRSSi pace a E cokes e USE 58 S Safety os sos diui sese Pash agate 8 23 Safety Decals 24 27 Safety Symbols 8 Seat Latches sos edax 31 65 Shock Spring Preload Front 51 Shock Valving sse 52 Signal Words uuuesuuu 8 dence 63 115 Ski Alignment 114 Ski Pressute 2 eese tes 56 Slide Rail and Track Cooling 74 139 INDEX S Snow Build up 18 Snow Conditions 21 Spark Plugs esas eatin oe os 92 93 Specifications 118 119 SPEC C 15 Spring Preload IQ 54 Steering Inspection 113 Steering System 66 113 115 Stop Switch eret ee 78 SEODDIDE i tesserati ns 81 Storage Daily suus 82 Storage Extended 116 117 NI MES 62 Survival Preparation 11 Suspension Adjustments Front 50 52 Suspension Adjustments IQ 54 59 Suspension Adjustments Rear 53 59 Suspension Coupling IQ 57 Suspension Inspection 70 Suspension Lubrication Front 89 Suspension Lubrication Rear 88 Suspension Performance Tips 53 Suspension Front 50 Switches DOP 3 Coe eere ied dks 78 Throttle Safety 78 140
13. Engine Troubleshooting Unless you have experience and training in two cycle engine repair see your dealer if technical problems arise Problem Probable Cause Solution of spec Erratic engine oper Drive clutch binding SEE YOUR DEALER ating RPM during acceleration orload Driven clutch mal SEE YOUR DEALER variations function Harsh drive clutch Drive belt worn or Replace the drive belt engagement too narrow Excessive belt SEE YOUR DEALER sheave clearance Drive belt turns over Wrong belt for appli Replace the drive belt cation Clutch alignment out SEE YOUR DEALER Engine mount bro ken 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 121 TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive sys tem Probable Cause Broken drive clutch components Solution e SEE YOUR DEALER Bearing failure chaincase jackshaft or front drive shaft SEE YOUR DEALER Drive belt surface flat spots nspect and replace as needed Drive chain lo
14. 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 83 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 135 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 and component life continue maintenance checks at 1000 mile 1600 km intervals All necessary replaceme
15. Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of POLARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR POSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered o
16. T Throttle Cable Lubrication 89 Throttle Leye 25 eres 65 79 Throttle Safety Switch 65 78 Torque Stop cie err memes 107 Torsion Spring Preload IQ 55 TOWING cos ormie nre oet ee 82 Track Alignment 112 Track Inspection 69 108 Track Lubrication 109 Track Replacement 108 Track Tension 59 110 111 Track Warm Up 74 Track Warning 25 Traction Products 62 63 Transporting the Snowmobile 117 Troubleshooting Drive Belt Wear Burn 125 Engin oes het 121 123 IQ Suspension 124 V Vehicle Identification Numbers 7 W Warning Labels Decals 24 27 Wear Strips esc ee case nso 63 Weight Transfer 59 Windchill Temperature Charts 23 PMS 419 For your nearest Polaris dealer call 1 800 POLARIS or visit www polaris com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9924222 Rev 01 Printed in USA POLARIS EINER T IIT I I I T T OUT I MI
17. 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 114 MAINTENANCE Steering System Ski Skags WARNING Worn skis and or skags will adversely affect handling Loss of vehicle control may result causing serious injury or death See your dealer s studding chart for recommended skags If you install longer or more aggressive carbide skags than the original equipment it may also be necessary to add track studs to maintain proper vehicle control while turning on hard packed snow or ice 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 Some models are equipped with single skags Some models are equipped with dual skags Raise and support the front of the snowmobile so the skis are approximately 6 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 Skag 115 MAINTENANCE Extended Storage Off season or extended storage of your snowm
18. 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 130 WARRANTY Conditions and Exclusions 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 component alignment tension adjustment or altitude compensation failure due to snow wat
19. 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 126 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 127 WARRANTY Limited Warranty POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 provides a ONE YEAR LIMITED WARRANTY on all components of the POLARIS snowmobile against defects in material or workmans
20. in your area or visit the American and Canadian online avalanche centers at www avalanche org 17 SAFETY Operator Safety Ice and Snow Build up WARNING Ice and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage If your snowmobile is equipped with RIDER SELECT perform this check in both the full up and full down steering positions Driving Downhill When riding downhill shift your weight to the rear of the snowmobile and reduce your speed to a minimum Apply just enough throttle to keep the clutch engaged allowing the engine s compression to help slow the snowmobile and keep it from rolling freely downhill WARNING When driving on long downhill stretches pump the brakes Riding the brakes may cause the brake system to overheat which may result in brake failure 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 op
21. l l Ignition Switch l l l I l Taillight 71 l l l Brakelight 71 l l l Headlight 71 I I l 86 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 1550mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CHASSIS Ski Toe Alignment l l l Suspension Mounting l l l I l Bolts Steering Fasteners l l l I C Rear Suspension Fas l l l I l teners Suspension Shock Oil I l I l Cooling Fins and I l I I Shroud Drive Shaft Bearing 89 L L L l Jackshaft Bearings 116 L L L l Skags Wear Bars 115 l l l I l Ski Saddle Spindle l l l I l Bolts Drive Chain Tension 99 l l l l l Hood Latches 66 l l l l l Rear Wheel Idler Bolts 111 l l l l l Idler Bolt Jam Nut 111 l l l l l Rear Suspension Pivot 88 L L L Shafts Steering Post U Joint L L L Camber Alignment l l I Handlebar Centering l Tether Switch and Strap 71 l l l I l Track Alignment 112 l l l l l Track Tension 110 l l l l l Front Limiter Strap l l l l l Rail Slide Condition 112 l Chaincase Oil 90 l l l R Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 87 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Main
22. or seas 96 Cooling System sss 96 98 Cooling System Bleeding 98 Cooling System Flushing 97 138 D DET ierit ERR RR PR EE 35 Detonation Elimination Technology 35 Digital Display 36 Disabled Operators 14 Drive Belt Adjustment 105 Break In 2s oce as 73 Condition sce oes 105 Deflection erm rm 105 Installation 107 Removal vcre Sane de 106 Salebyi ier eme are ue ee s 20 Drive Chain Tension 99 Driver Awareness 16 Driveshaft Bearing Lubrication 89 Driving Downhill 18 Driving in Hilly Terrain 19 Driving on Slippery Surfaces 19 Driving Responsibly 22 E Emission Control Information 83 Emission Control Label 83 Emission Control Maintenance 83 Emissions Limited Warranty 133 134 Engine Break In 72 73 Engine Stop Switch 78 Environment Preservation 6 Exhaust System 95 Eye Protection 12 F Front Rear Scissor Stop 57 Front To Rear Coupling 57 ERSS 2 cec ewe meit EL EVER 57 E el ioi 0h oil geh ee dd mA 76 F Fuel Filt t 2 2 rre 94 Fuel Injectors seese nass Rn 94 Fuel Lam eS eit sats ales A E 94 Fuel Premix Initial Fill 72 Fuel Pump spare depo 94 Fuel Safety 2e 75 Fuel System Deicers 76 G Gauge Cleaning
23. runner skag Condition Ski spindle bolts Tightness Tie rod end nuts Tightness 70 PRE RIDE INSPECTIONS Start the Engine and Check Engine Stop Switch Check the auxiliary shut off switch for proper operation Push the switch down to stop the engine Pull it up to allow restarting 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 Tether Switch if equipped If your machine has a tether switch remove the tether from the switch to make sure the engine stops immediately Operating Area Before driving away check your surroundings Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile 71 OPERATION Break In Period Engine Break In Always follow these recommended break in procedures for new or rebuilt engines The first tank of fuel is considered the break in period for the engine Premix the 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 fast
24. the system is bled properly they ll be warm to the touch If they re not repeat step 5 Lift the front of the machine slightly to assist in the bleeding 8 Replace the pressure cap and carefully lower the front end of the machine 98 MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip To obtain correct chain tension Rotate the driven clutch counter clockwise to move all chain slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut 1 3 Finger tighten the adjuster bolt 2 until it can no longer be adjusted by hand then back off 1 4 turn 4 Tighten the jam nut while holding the adjuster bolt Torque to 21 ft Ibs 28 Nm 5 Release the brake lever lock 99 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile See page 67 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 Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the back
25. 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 126 132 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 the date the vehicle is first purchased and continues for a period of 200 hours of engine operation 4000 kilo meters 2485
26. 043512 5136402 78P 2400 3000 10 56 Black Green 120 210 P2 Tab 42S P2 22 43 8000 10000 1321684 7042083 7043512 5136402 78P 3000 3600 10 54 Black Green 120 210 P2 Tab 42S P2 22 43 10000 12000 1321685 7042083 7043512 5136402 78P 119 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 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 1 2877884 VES 2 Cycle Engine Oil 2 5 gal 9 5 Chaincase Lubricants 2873105 SCL Synthetic Chaincase Lubricant qt 95 1 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 120 TROUBLESHOOTING
27. 4 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 B 2 km Tip The direction of the arrows indicates the direction of flow through the fil ter Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 85 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 Close the hood 95 MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60 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 120 for the part numbers of POLARIS products Tip Never add tap water to the cooling system Minerals cause d
28. Hayes Phantom DOT 4 Drive Clutch Center Distance 11 5 in 29 cm Drive Belt P N 3211122 Clutch Type P 85 Reverse Transmission Electronic Reverse Engine and Cooling Engine S4768 6044 OR6H Displacement 599 cc Cylinders 2 Bore x Stroke mm 77 25x64 Alternator Output 400 watt Throttle Body Mikuni Throttle Body Bore Size 46mm Idle RPM 1700 200 Cooling Liquid Ignition Type Digital Ignition Timing 18 BTDC 1700 RPM water temp 120 F 49 C Spark Plug Gap Champion RN57YCC 027 in 0 70 mm Fuel Octane 91 Recommended 87 Minimum Electric Fuel Gauge Standard Electric Start Standard Low Oil Light Standard Parking Brake Standard Speedometer Standard Tachometer Standard 118 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 10 64 Black Green 120 210 P2 Tab 42S P2 22 43 0 2000 1321585 7042083 7043512 5136402 78P 600 1200 10 62 Black Green 120 210 P2 Tab 42S P2 22 43 2000 4000 1321586 7042083 7043512 5136402 78P 1200 1800 10 60 Black Green 120 210 P2 Tab 42S P2 22 43 4000 6000 1321587 7042083 7043512 5136402 78P 1800 2400 10 58 Black Green 120 210 P2 Tab 42S P2 22 43 6000 8000 1321588 7042083 7
29. PM and Service Interval settings Maximum Speed Maximum RPM Enter the History Program L 2 Press and release the SET button until 7 one of the two screens is active MAX MPH F Tip The MPH and RPM values are both reset at e the same time Reset the values before each hr z E E run to obtain accurate readings 3 Press and hold the SET button for three 1 ex 1 seconds to reset the recorded maximum f J values for both MPH and RPM d Tip Due to electrical noise the MFD may occa MAX RPM p sionally display MAX MPH RPM values that are not representative of actual values Fy hr 3e 45 FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine a hours accumulated between service fi reminders When the logged hours reaches the designated service interval set by the user the gauge provides a ENG F reminder that service is due SErVCE j will flash in the odometer area and SE rM CE z ENG will flash in the icon area for five seconds each time the engine is started until the service reminder is reset Use the following procedures to reset the reminder To reset the reminder at the existing interval 1 Enter the History Program 2 Press and release the SET button until the service interval screen is active 3 Press and hold the SET button for ten seconds continuing to hold even af
30. RIDER SELECT position 6 or 7 will result in the handlebars and brake lever contacting other components and interfering with steering and braking This could lead to loss of control resulting in serious injury or death Always be sure that the handlebars and brake lever do not contact any other snowmobile components at any steering position AND at any RIDER SELECT position Do not use RIDER SELECT positions 6 or 7 unless riding conditions require it Operation in position 6 or 7 can reduce vehicle handling for other types of riding and result in serious injury or death Choosing the Best RIDER SELECT Position Position Riding Style 1 Relaxed Trail Riding 2 Rider weight is slightly behind the center of the snowmobile for comfortable and 3 relaxed riding 4 General Trail Riding Boondocking 5 Deep Snow Riding Rider weight is centered on the snowmo bile providing balance comfort and con trol for both novice and experienced riders This is the recommended position for most riding situations 6 Snowcross Steep Hill Climbing Only 7 Rider weight is ahead of the center of the snowmobile adding weight to the skis and making the snowmobile heavier in the front These positions are ONLY for snow cross and severe hill climbing 23 FEATURES RIDER SELECT Adjustable Steering System WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of cont
31. Replacement When replacing the track always install a track having the lug size rec ommended for your model See your POLARIS dealer NOTICE Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel Always install a track having the lug size recommended for your model Track Inspection WARNING Broken track rods can cause a rotating track to come off the machine which could cause serious injury or death Never operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and sup port the rear of the snowmobile off the ground 2 Rotate the track by hand to check for damage 3 Carefully examine the track along the entire length of each rod Bend the track to check for break age 4 Replace the track if any rod dam age is found 108 MAINTENANCE Track Lubrication WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid operating for ees periods on ice and other surfaces that have little or no snow for ubrication The slide rail requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear Track damage or failur
32. Safety Drive Belt Do not operate the engine with the drive belt removed Any servicing that requires operation without a belt must be performed by your dealer NOTICE Operation of the engine with the belt removed may result in damage to the engine Intake Silencer Do not operate the engine with the intake silencer or filter removed NOTICE Damage to the engine may occur if the intake silencer or filter are removed Clutches Do not attempt to service the clutches All clutch service must be performed by your dealer The clutch is a complex mechanism that rotates at high speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the throttle with enough authority to put the snowmobile into motion but always operate within safety limits and on 2 up machines with respect for a passenger 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 Sin
33. 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 counter clockwise an additional 1 4 turn by hand and try again Grasp the belt at the lower edge and remove it MAINTENANCE Clutch System Drive Belt Installation 1 Tip Drop the drive belt over the drive clutch and pull back the slack The belt cord line should be flush with or slightly above the outer cir cumference of the driven clutch sheaves The belt will seat itself in the driven clutch during the break in period Adjust the belt ride out after the break in period by read justing belt deflection To ensure satisfactory belt life install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as outlined in the belt removal procedures 2 Rotate the L wrench counter clockwise to tighten the sheaves while working the belt to the outer edge of the sheaves 3 Remove the wrench 4 Reinstall the side panel 5 Close and secure the hood 6 Break in the new belt See page 73 Torque Stop Periodically check torque stop clearance With 0107 030 clutches in proper alignment the torque stop 25 75 mm clearance should be 010 030 25 75 mm aS from the engine case Adjust if necessary Lock the jam nut q cal o 9 e e 9 e o ce 107 MAINTENANCE Track
34. Y from X sag X Y If the measured sag is incorrect adjust the FRA position and or rear torsion spring preload Suspension Recommended Sag Adjustment nd IQ Comfort 4 5 inches 10 13 cm Torsion Spring 55 136 Preload Tip This is only an initial setup and final spring preload may vary based on rider preference and riding conditions Accessory springs with a higher load rat ing are available for some models Please see your dealer for availability 54 THE PERFECT FIT IQ Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload rotate the three position cam using the engine spark plug tool Adjustment is easiest when the cam is rotated from low to medium and then to high Rotating directly from low to high will require significantly more effort Different rate torsion springs are available if a firmer ride is desired See your dealer for more information Soft Medium Firm 55 THE PERFECT FIT IQ Rear Suspension Adjustments Limiter Strap Position Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling If a rider prefers more ski pressure for improved steering performance adjustments can be made to the p 9 ae AR front limiter straps Tighten the TN straps to increase ski pressure SA Loosen the straps to reduce ski FDO e f pressure EN 1 Remove the nuts and flat washers from the upper limiter st
35. aight 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 Drive Belt Adjustment 1 Install the L wrench into the open threaded hole in the outer sheave of the clutch see page 106 Turn the wrench clockwise slightly to remove pressure from the sheaves 2 Loosen the 7 16 jam nut on the belt width adjuster 3 Using a 1 8 Allen wrench adjust the threaded set screw as needed Tip Turn the set screw in clockwise to increase the distance between the sheaves and out counter clockwise to decrease the distance 4 Tighten the jam nut 105 MAINTENANCE Clutch System Drive Belt Removal NOTICE Do not attempt to remove the drive belt after operating in reverse The ON OU de US 106 snowmobile must be stopped after forward motion to prevent damage to components during belt removal Stop the engine after operat ing in a forward motion Turn the ignition key off Wait for the engine to come to a complete stop Lock the parking brake Open the hood Remove the left side panel Rotate the driven clutch counter clockwise 1 4 turn by hand to ensure forward engagement before attempting to remove the belt Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch X
36. alance for proper control Rider positions may vary with experience but under many conditions the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle brake and steering control WARNING Improper riding position may reduce control and could result in serious injury or death Always ride in a position that allows for control of your vehicle Survival Preparation For your safety always ride in a group of other snowmobilers Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is not lim ited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cel lular telephone Always carry the owner s manual on your snowmobile For added pro tection purchase and carry the following items on your snowmobile as well Spare Drive Belt Winter Survival Kit Extra Set of Spark Plugs Trail Map Tow Rope First Aid Kit Extra Oil Tool Kit Fuel Deicer 11 SAFETY Operator Safety Riding Apparel Helmet Wearing a helmet can prevent a severe head injury Whenever riding a POLARIS vehicle always wear a helmet that meets or exceeds estab lished safety st
37. an occur without the proper lubrication Check the oil tank level often during the first tank of fuel If the oil level doesn t go down contact your dealer immediately Drive Belt Break In The break in period for a new drive belt is 30 miles 48 km During this time vary the throttle position under 5046 and limit full throttle use New drive belts should be washed with warm soapy water and allowed to air dry prior to use Always take time to warm up the belt and driveline prior to operating the snowmobile Free the track and skis from the ground before engag ing throttle T3 OPERATION Slide Rail and Track Cooling NOTICE Inadequate cooling and lubrication will lead to overheating of the slide rail and track resulting in premature wear and failure Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces Avoid operating on ice hard packed surfaces or roads Track Warm Up A loose track or flying debris could cause serious injury or death Stand clear of the front of the machine and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throttle during warm up or when the track is free hanging Be sure the rear support is stable A 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 re
38. andards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be prepared be warm and be com fortable when riding Be aware of the weather forecast especially the windchill and dress accordingly See the chart on page 23 WARNING Avoid wearing loose clothing or long scarves which can become entangled in moving parts and cause serious injury Always wear an approved helmet and eye protection 12 SAFETY Operator Safety Rider Capacity Driving 1 Up Some POLARIS snowmobiles are designed for a single rider only A decal on the console of these models indicates single rider operation Driving 2 Up Some POLARIS snowmobiles are designed for up to two riders A decal on the hood of these models indicates tha
39. ant identification numbers that should be recorded in the owner s manual Safety D MrM 8 This section describes safe vehicle operation and identifies warning decals and their locations Features caxac swa ka RORORXCR E RR EORR EO KE 28 This section identifies the locations of your snowmobile s controls and features The Perfect Fit 50 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 64 This section explains procedures that must be performed before riding Operation 25 2 RRRRERRReERGeExa xS en 72 This section explains proper engine break in operation of features and general operating procedures Maintenance esernn 83 This section defines your role and your dealer s role in your snowmo bile s regular maintenance Specifications Leere 118 POLARIS Products 120 Troubleshooting Lssse 121 Warranty euscuuERERETSSPRRESTERPERSEE EE 126 Maintenance Log LL 135 IndeX eo iRsuRERRRRRRRRPRERERRA ERREUR E 138 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
40. arm Adjusting the RRSS either allows more weight to transfer to the rear for more traction or allows less weight to transfer to the rear resulting in improved cornering performance An adjustment dot is located on the RRSS This dot is on the longest end of the scissor stop Rear Rear Scissor Stop RRSS Attributes Moving the RRSS to a higher position will have the following effects on the suspension Reduced weight transfer mproved chatter bump ride mproved cornering performance ncreased load carrying capacity 2 up 58 THE PERFECT FIT IQ Rear Suspension Adjustments Weight Transfer During Acceleration The preferred method for controlling weight transfer during acceleration is HIGH by adjusting the rear rear scissor stop RRSS The factory setting is the SM id MEDIUM best for most trail riding conditions To decrease weight transfer under acceleration for improved corner ing rotate the RRSS to a higher position To increase weight transfer or ski lift during acceleration rotate the RRSS to a lower position Tip Your dealer can help you with initial setup and additional setup instruc tions to help you achieve your opti mum ride A scissor stop tool is also available from your dealer Track Tension Track adjustment is critical for proper handling Always maintain cor rect tension and alignment Refer to the track tension maintenance sec tion beginning on page 110 59
41. ause 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 harm Operate this vehicle only outdoors or in well ventilated areas 75 OPERATION Fuel For peak performance POLARIS recommends the use of 91 octane or higher fuel Although 87 octane fuel is usable some engine perfor mance will be lost and fuel economy will decrease Do not use lower than 87 octane fuel Do not use fuel containing more than 1096 ethanol including E85 NOTICE Operating with obstructed fuel systems will result in serious engine damage Perform maintenance as recommended Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel Fuel System Deicers If you use non oxygenated fuel POLARIS recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline to prevent engine damage resulting from fuel system icing and lean fuel mixtures Never use deicers or additives containing methanol POLARIS also recommends the use of Carbon Clean See page 120 for the part numbers of POLARIS products If you use oxygenated fuel containing ethanol additional alcohol deic ers or water absorbing additives should not be used 76 OPERATION Cil Low Oil Indicator Light The low oil indicator light may flicker at times due
42. ce 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 throttle is opened the snowmobile will be able to climb up and over the snow 21 S AFETY Operator Safety Driving Responsibly Every snowmobile handles differently and even the most docile condi tions may become dangerous if operators drive improperly If you re ne w 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 exe
43. cuting 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 your speed When traveling in a group of snowmobiles don t tailgate follow too closely Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions Be aware of any snowmobile traffic around your vehicle Drive defen sively to avoid accidents Remove the key from the ignition when you leave the snowmobile unattended Operator Safety Windchill Temperature Charts SAFETY The following information
44. d ae WM Engine Temp as oe B B 36 FEATURES Instrumentation MFD Settings The MFD control switch allows you to set the MFD display to your pref erences The rocker switch has a MODE button top and a SET but ton bottom Specific instructions are outlined on the following pages Standard vs Metric The MFD will display either stan dard or metric units of measurement While viewing a screen that displays measurements MPH km h or tem peratures press and hold the MODE switch until the unit of measure ment changes about 10 seconds 37 FEATURES Instrumentation MFD Settings Speedometer Tachometer The speedometer and tachometer can be viewed in either the analog or the digital display If the analog display is set to show speedometer readings the digital screen will automatically display the tachometer option 1 If the analog is set to show the tachometer the digital screen will show the speedometer option 2 To change viewing preferences press and hold the MODE button for three seconds When the button is released the new setting becomes active and screen colors change See table below Option Analog Digital Analog Digital P Display Display Screen Screen 1 Speed RPM Blue MPH Blue Backlight 2 RPM Speed Red Red X100RPM Backlight 38 FEATURES Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle throug
45. differ Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals 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 b
46. e Decreasing spring preload will decrease ski to ground pres sure When adjusting be sure the springs on both the left and right sides of the machine are at the same adjustment To change front shock spring preload grasp the spring and rotate it Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension Never exceed one inch of pre load beyond the factory settings and ensure that both sides are adjusted the same When decreasing preload make Low High sure at least two turns of preload are hold Preload Preload ing the spring between the retainer on the top of the shock and the threaded spring preload adjuster nut on the shock body Failure to do so could cause the retainer to fall off when the suspension is fully extended Tip Not all models have shocks with thread adjustable spring preload See your dealer for more information NOTICE On some models equipped with a plastic adjuster nut the nut will break if it is unscrewed from the threaded body Do not force the nut if resistance suddenly increases while you re turning it 51 THE PERFECT FIT IQ Front Suspension Adjustments Shock Valving The shocks can be revalved if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness WARNING Changing shock valving requires spec
47. e outside of the compartment i Carefully cut the bottom of the compartment opposite the wires to separate the heat sealed seams Squeeze the corners of the compart ment inward so the battery is visible Note the orientation of the battery before removing it An incorrectly installed battery will not maintain the clock FEATURES Instrumentation MFD Battery Replacement gt Tip Using needle nose pliers grasp the battery and rotate it so the lead ing edge of the battery is raised away from the battery holder Pull the battery out gently The battery will not come out of the holder unless the leading edge of the battery is raised Hold the battery compartment not the wires while remov ing the battery Pulling on the wires will separate them from the battery holder Install a new battery with fingers only Seal the end of the battery compartment using high strength double sided tape between the two compartment halves or high strength single sided tape around the outside of the compartment Make sure the taped seam of the compartment faces the downward side of the wire harness Install a cable tie to secure the compartment to the wire harness in the same location where the previous cable tie was located Make sure the battery wires are not stretched tight Gauge Cleaning 1 2 Wipe the gauge face as needed using a clean cloth and a mild soap and water solution Wipe dry with clean soft cloth Clea
48. e caused by operation on ice or under other poor lubrication conditions will void the track warranty NOTICE High speed use on hard packed surfaces is not recommended for models equipped with a deep lug track Track lug damage may occur Keep high speed use to a minimum including frequent slow speed intervals for track cooling 109 MAINTENANCE Track Tension WARNING Moving parts can cut and crush body parts When performing the checks and adjustments recommended on the following pages stay clear of all moving parts Never perform track measurement or adjustments with the engine running Track adjustment is critical for proper handling Always maintain cor rect tension and alignment TRACK TENSION DATA CHART Suspension Slack Measurement Weight Measurement Location IQ Comfort 7 8 1 1 8 2 2 2 9 cm 10 Ibs 16 40 cm 4 54 kg ahead of rear idler shaft Tip Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the snowmobile and safely support it off the ground 3 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 Tip Measure at the point where the weight is hanging 110 MAINTENANCE Track Tension 4 Check for specified slack between the wear surface of the track clip and the plastic rail slide If the track needs ad
49. e is equipped with an electronic fuel gauge Trip F automati cally displays when the fuel level is low The fuel symbol and the last fuel bar on the MFD gauge will blink when the fuel level reaches 1 8th tank The Trip F odometer records distance traveled until enough fuel is added to raise the level above 1 4 tank The fuel symbol and the fuel bar will continue to blink until the fuel level is above 1 4 tank The Trip F odometer will automati cally reset to zero after refueling FEATURES 41 FEATURES Instrumentation MFD Digital Display Programs Performance Program Clock Setting if equipped Enter the Performance Program l H5 LU 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 42 FEATURES Instrumentation MFD Digital Display Programs Engine Program The Engine Program automatically displays the engine coolant tempera ture engine hours electrical system voltage le
50. e ride n deep snow a new rail slide will offer improved performance over a worn slide It can also improve top speed When riding on ice or hard packed snow adding a set of bogie wheels to the rail may enhance the machine s performance Bogie wheel kits are available from your dealer 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 89 53 THE PERFECT FIT IQ Rear Suspension Adjustments Initial Spring Preload Setting Sag Method To set up the rear suspension torsion spring preload measure the distance 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 lifted upward slightly to fully extend the rear suspension 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 and the rear bumper at the exact location used for measure ment X This is measurement Y To determine sag commonly referred to as ride in subtract measure ment
51. e sure there s adequate stud clearance to the heat exchangers Lack of clearance may result in damage to heat exchangers 63 PRE RIDE INSPECTIONS Pre Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile Procedures are outlined on the refer enced pages Item See Page Drive Belt Condition 105 Steering System 66 Recoil Rope 65 Parking Brake Lock Brake Lever Brake System 67 68 100 Throttle Lever 65 Throttle Safety Switch 65 Auxiliary Shut Off Switch Engine Stop Switch 71 81 Ignition Switch 71 81 Taillight Brakelight Headlight 71 Coolant Level 96 Chaincase Oil Level 90 Injection Oil Level 77 Suspension Mounting Bolts 70 Skags Wear Bars 63 115 Ski Saddle and Spindle Bolts 70 Hood Straps Latches 66 Seat Latches 65 Rear Wheel Idler Bolts 70 111 Track Alignment Condition 69 112 Rail Slide Condition 112 64 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 O
52. eck 1 Position the vehicle on a level sur face 2 View the oil level at the sight glass 3 Remove the fill plug 3 and add the recommended oil as needed Do not overfill 4 Reinstall the fill plug making sure it is seated properly 90 MAINTENANCE Chaincase Oil Oil Change 1 2 po SI o pa Position the vehicle on a level surface Remove the drain plug 4 and drain the oil into a drain pan Allow the oil to drain completely Clean off all metal shavings from the plug Install a new sealing washer on the drain plug The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 6 10 ft Ibs 8 13 Nm Remove the fill plug Clean off all metal shavings from the plug Add 11 oz 325 ml of the recommended oil Do not overfill Reinstall the fill plug making sure it is seated properly 91 MAINTENANCE Spark Plugs A new engine can 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
53. ed tracks are used increased wear to the brake pads will result from increased braking Extended wear brake pad kits are avail able See your dealer NOTICE Aggressive studding patterns may require grinding protruding stud bolts flush to prevent idler wheel damage Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger damage Center of stud must be at least 1 1 8 2 86 cm from the outside edge of the track 62 THE PERFECT FIT Traction Products Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain Use carbide skags with studded tracks to help maintain proper vehicle steering and control See page 115 If your snowmobile has carbide skags it may be necessary to add track studs to maintain proper vehicle control Maintain a proper balance between the number of studs and the length of carbide on the skags the more studs you use the longer the carbide on the skags should be See your dealer s track studding chart Wear Strips To avoid excessive tunnel wear tunnel wear strips must be installed whenever track studding is used Install the appropriate wear strip kit See your dealer Wear strips are designed for a specific stud length See your dealer s studding chart for recommended traction accessories NOTICE Whenever wear strips are relocated b
54. ee page 59 Machine darts from side to side Check ski alignment see page 114 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Set static sag see page 54 Check rail slide replace if worn see page 112 Install Accu Trak dual skags see your dealer Front end pushes Check for worn skags Check for binding front suspension shafts and steering components grease all pivot points elevate front of machine Set static sag see page 54 Install single skag see your dealer Increase IFS preload if equipped see page 51 Rotate RRSS to higher position see page 59 Steering is heavy Make sure spindles and all steering components turn freely Check ski alignment see page 114 Check skags and skis for damage Set static sag see page 54 124 TROUBLESHOOTING Drive Belt Wear Burn Cause Driving at low RPM Solution Drive at higher RPM Gear the machine down Check belt deflection Insufficient warm up Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and warm it up Break machine loose from the snow Towing at low RPM Do not tow in deep snow Use fast aggressive throttle to engage clutch Riding with high RPM Lower the gear ratio Reduce RPM Avoid riding in high and slow speed 8000 ambient t
55. eed when driving at night or in inclement weather Always observe all state and local laws governing snowmobile opera tion and speed limits Always be alert and pay attention to the trail ahead If your speed is 40 MPH 64 km h your snowmobile is traveling about 60 feet 18 m per second If you look back for only two seconds your snowmobile will travel about 120 feet 36 m If your speed is 60 MPH 96 km h your snowmobile will travel about 180 feet 55 m in two seconds Traveling at night requires extra caution Check headlight and taillight to ensure proper operation and don t over drive your headlight beam Always be able to bring your snowmobile to a stop in the distance illu minated by the headlight 15 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles posts or other obstacles Be especially alert if you re snowmobiling after dark Always be on the alert for wire fences Single strands are especially dangerous since there may be a great distance between posts Guy wires on utility poles are also difficult to distinguish Make sure the way is clear before crossing railroads and other roads and highways The noise of your snowmobile will drown out the sound of approaching vehicles A Look ahead behind and to both sides before turning or crossing railroad tracks or highways Steep embankments may also hide your view Always leave yourself a way out Variances in snow depth and or
56. emperatures Check for snow ingestion RPM 10 MPH 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 engage ment 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 125 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty infor mation 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 mainte nance which may supersede information contained in this manual Your dealer is also familiar with POLARIS policies and procedures
57. eposits and may react adversely with the metals in the engine and cooling system Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are Coolant reservoir bottle Filler neck Pressure cap Connecting hoses Always maintain the coolant level at the COLD FILL mark on the coolant overflow tank 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 96 MAINTENANCE Cooling System Coolant High Temperature Indicator Light The high temperature indicator light will illuminate when engine cool 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 drain the system completely every two years and add a fresh mixture of antifreeze and distilled water This service must be performed when the engine is cold Ask your POLARIS dealer to check the coolant whe
58. er dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship 131 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from POLARIS Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your vehicle was purchased War
59. er than the VES oil See page 120 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 72 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 recommend the use of POLARIS lubricants for your vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the snow mobile Oil Injection System Always check and fill the oil tank when refueling See page 77 NOTICE Serious engine damage c
60. er to resolve any warranty issues Your dealer will contact the appropriate personnel at POLARIS if additional assistance is needed This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of POLARIS engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 129 WARRANTY Conditions and Exclusions In order to qualify for warranty the product must have been properly set up and tested by a POLARIS Dealer if applicable Failure of any dealer to perform the required vehi cle Pre Delivery Inspection perform all applicable service bulletins and have the con sumer sign the PDI form prior to delivery may void the warranty Failure to provide proof of required periodic maintenance upon request may result in denial of warranty coverage Use of the recommended POLARIS products for lubrication and maintenance as directed by the Owner s manual is highly recommended Should a failure occur dur ing the warranty period resulting from the use of non recommended products warranty coverage may be denied Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination
61. erating SEE backfires 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 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 etha nol 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 get ting to engine SEE YOUR DEALER Engine backfires but fails to start Spark plug wires may be on wrong cylinder Reinstall spark plug wires to the cor responding cylinder 123 TROUBLESHOOTING IQ Comfort Suspension Troubleshooting Problem Solution Rear suspension bot Adjust torsion spring preload to achieve proper static sag toms too easily see page 54 Change torsion spring to stiffer optional spring see your dealer Rotate RRSS to higher position see page 59 Rides too stiff in rear Check for binding suspension shafts and grease all pivot points Adjust torsion spring preload to achieve proper static sag see page 54 Change torsion spring to softer optional spring see your dealer Check track tension see page 110 Rotate RRSS to lower position s
62. erating 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 down the hill Stop the engine and set the parking brake if equipped Keeping away from the downhill side of the snowmobile pull the rear of the snowmobile around and point the front end and skis downhill Remount the snowmo bile restart the engine release the parking brake and descend the hill carefully 19 SAFETY Operator
63. gine 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 havea p warning decal on the left console One Passenger For more information on operating Warning with a passenger 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 I W Track Warning 25 SAFETY Safety Decals and Locations Reverse Warning Operation Warning Reverse Warning POLARIS snowmobiles equipped with electric 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 If electric reverse Machine stopped and engine at id
64. h the three MFD pro grams Performance Engine and History Each program remains active until you cycle to the next program While any program is active press and release the SET button to cycle through the program s screens Performance Program The Performance Program automatically displays either speed or tachometer whichever is opposite the analog display See page 38 It also displays electrical system voltage and fuel level if equipped While in the Performance mode press the SET button to cycle through the odometer Trip 1 Trip 2 Trip F if equipped with electronic fuel gauge and Clock if equipped Use the following procedures to make changes to these screens Odometer Setting The odometer records the vehicle s total j nc fi distance traveled since manufacture The odometer cannot be reset oth 39 FEATURES Instrumentation MFD Digital Display Programs Trip Settings Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled Both LU odometers can be reset to zero MILES 1 Enter the Performance Program A 2 Pressandrelease the SET button C L until the desired trip screen is active 3 Press and hold the SET button for two seconds to reset the trip odometer to zero 4 Press and release the SET button to cycle through additional screens 40 Instrumentation MFD Digital Display Programs Performance Program Trip Settings If the snowmobil
65. hip 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 tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected impr
66. ial tools and a sound knowledge of mechanical theory tool use and shop procedures to perform the work safely and correctly Shocks contain high pressure nitrogen gas Use extreme caution when handling high pressure service equipment We recommend that this work be performed by a POLARIS dealer 52 THE PERFECT FIT Rear Suspension Adjustments Rider weight riding style trail conditions and vehicle speed all affect suspension action Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions However all sus pension 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 Refer to the suspension setup label on your snowmobile or see your POLARIS dealer for initial suspension setup information Additional adjustments can be made after initial setup Make adjustments to one area at a time so you can evaluate the change For further assistance see your 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 th
67. ing plate approximately 1 16 1 5mm Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thickness is less than 1 16 1 5 mm Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops bring the snowmobile to an authorized POLARIS dealer for inspection and adjustment 100 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 Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid See page 120 for the part numbers of POLARIS products The brake fluid level can be seen through the fluid level indicator a plastic sight glass in the master cyl inder reservoir If the fluid is suffi cient the sight glass will be black If the sight glass is any col
68. ing 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 ndn Minimum POLARIS rail slides have a Thickness wear limit indicator groove to indicate the minimum per xN missible slide thickness Replace the rail slides if they are worn to the top of the groove at any point along Replace when their length Failure to do so worn to top of may result in permanent grooye damage to the track or rails 112 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride Tighten any loose fasteners ds IL UI hd 3n gel I it aan SES Si oe 113 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
69. is provided to help you determine when tem peratures become dangerous for riding WIND CHILL CHART F Wind Actual Thermometer Reading F Speed 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 MPH Equivalent Temperature F Calm 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 5 36 31 25 19 13 7 1 5 11 46 22 28 34 40 46 52 57 63 10 34 27 21 15 9 8 4 30 16 22 15 32 25 19 13 6 O0 7 13 19 26 20 30 24 17 1 4 2 9 15 22 28 25 29 23 16 9 3 4 1 17 24 81 30 28 22 15 8 1 5 12 19 26 88 35 28 21 14 7 0 7 A4 21 27 34 40 27 20 13 6 1 8 45 22 29 86 45 26 19 12 5 2 9 46 23 80 87 50 26 19 2 4 3 10 17 24 31 38 55 25 18 1 4 8 11 18 25 32 39 60 25 17 10 3 4 t1 19 26 33 40 Frostbite in gt gt 30 min 10 min WIND CHILL CHART C Wind Actual Thermometer Reading C speed 5 2 3 10 13 16 19 22 25 28 31 34 37 40 43 46 Km h Equivalent Temperature C Caim 5 21 1 4 7 10 13 16 19 22 8 3 0 4 7 t 14 18 22 25
70. justment 5 Loosen the rear idler shaft bolt 6 Loosen the lock nuts Adjusting Screw Slack Measurement Lock Nut 16 40 cm ens 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 gt l 1 4 54 kg 10 Check track alignment see page 112 and adjust as necessary 11 Tighten the lock nuts 12 Tighten the idler shaft bolts Torque to 35 ft Ibs 47 5 Nm 111 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 Start the engine and apply a small 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 adjust
71. l Hood Hold Down Straps Fuel Filler Cap Rider Select 29 FEATURES Backrest The backrest can be adjusted for rider comfort Whenever making adjustments always make sure all lock levers are securely locked before operating Tip If an adjustment is difficult rotate the lock levers to relieve tension then Height Adjustment 1 2 Angle Adjustment 1 2 make the adjustment Lift the upper lock levers 1 on both backrest supports to release the locks Raise or lower the backrest to the desired position Push the lock levers inward to secure the locks Lift the lock lever at the center of the backrest 3 Tilt the backrest forward or rearward to the desired position Push the lock lever inward to secure the lock Operator Passenger Conversion 1 30 Lift the lower lock levers 2 on both backrest supports to release the locks Move the backrest forward for operator use or rearward for passenger use Push the lock levers inward to secure the locks FEATURES Adjustable Headlights Move the adjuster to the left to lower the headlight beam Move the adjuster to the right to raise the headlight beam Radiator Compartment Access Panel The access panel is provided for cleaning debris from the radiator Cargo Bag The cargo bag is secured to the rear of the tunnel with straps The cargo bag and the passenger seat are removable to provide open storage for transporting large
72. l l l l Clutch Sheaves 104 l l l l ENGINE COOLING Engine Mounts l l I l Recoil Rope l l l l Engine Torque Stop 107 l l I l Cylinder Head Bolts l l I Oylinder Base Nuts l l l I Ignition Timing BTDC l l I VES System C C C l Coolant 96 l l R l Coolant Hose l l l l Heat Exchangers 98 l l l I I Coolant Circulation l l l Coolant Leaks l l l l Spark Plug Condition 92 I l l R l Exhaust Pipe 95 l l Exhaust Retaining 95 l l l l Springs Inspect clean adjust tighten lubricate replace if necessary C Clean R Replace L Lubricate 85 MAINTENANCE Periodic Maintenance Interval Table Item See Frequency Page 750 mi 500 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 100 l l l l Brake Disc l l l l Parking Brakes 68 l l l l Brake System 67 l 100 Brake Fluid 101 l FUEL MANAGEMENT Idle RPM l l Throttle Lever 65 79 I l I I l Oil Pump Lever l I l synchronize Throttle Cable 89 L L L Throttle Position l l l Sensor Fuel Lines 94 I l I I l Fuel Filter 94 R Every 2000 mi 3200 km or Every 2 years Oil Filter 95 R R Oil Lines 95 l l l Air Box l l l l l ELECTRICAL Auxiliary Shut Off 71 78 l l I l l Switch Throttle Safety Switch 78 l l l
73. le push yellow button on LH con trol to reverse Flashing light on dash indicates reverse operation Push button again to return to forward SAFETY Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all POLARIS snowmobiles AWARNING e To avoid serious injury or death read and understand all warnings and the Owner s Manual before operation If manual is missing contact a POLARIS dealer for a replacement This vehicle is capable of high speeds Buried objects or uneven terrain can cause loss of control Reduce speed and use extreme caution when operat ing 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 vehicle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then pull the brake lever to stop Always wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age require ments When operating with a passenger on approved models only reduce speed and allow extra space for steering and stopping A passenger reduces your ability to control the vehicle When operati
74. m Periodically inspect clutch sheaves for damage wear or belt residue To maintain optimum performance clean with non oil based cleaners such as isopropyl alcohol WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern see your dealer immediately Do not operate the snowmobile until repairs have been made WARNING All clutch maintenance and repairs must be performed by an authorized POLARIS dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty 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 See your dealer for service and adjustments A special tool is required to check for proper alignment 104 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 125 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 Str
75. miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehi cle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Ignition system Fuelsystem Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emis sions e Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emis sions Fuel Tank Vacuum Control Diaphragms e Fuel Cap Control Cables Fuel Line Control Linkages Fuel Line Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves e Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 133 WARRANTY U S A EPA
76. move the drive belt before towing and have someone ride on the towed snowmobile to operate the brake and steering when necessary NOTICE Towing a disabled snowmobile with the drive belt in place can result in serious damage to the engine and drive system Always remove the drive belt from a disabled snowmobile before towing 82 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 con trol information ECI label and a factory installed emissions informa tion 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 for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual
77. n he performs the fall tune up on your snowmobile 97 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 Position the vehicle so that the top of the tunnel is level Elevate the front of the vehicle slightly if necessary 2 Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark 3 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 4 Add coolant to the coolant bottle to the maximum mark 5 Start the engine and run at a fast idle for two to three minutes Loosen the bleed screw occasionally to purge any trapped air 6 Stop the engine and check the coolant bottle level Fill as required 7 Feelthe heat exchangers under the running boards If
78. n the 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 come into contact with the lens Immediately clean off any gasoline that splashes on the gauge during refueling 49 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 time 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 Optional shock valving 50 THE PERFECT FIT IQ Front Suspension Adjustments Front Shock Spring Preload Increasing spring preload will increase ski to ground pressur
79. nd cable must return to the idle position quickly and completely If the throttle lever operates properly turn the ignition switch on and go through normal starting procedures If the engine doesn t start take the snowmobile to an authorized POLARIS dealer for service Excessive freeplay in the throttle cable may cause the safety switch to acti vate preventing the engine from starting If this occurs return the snowmo bile to an authorized POLARIS dealer for service If an emergency exists and it s necessary to start the engine the throttle safety switch and engine stop switch may be disconnected from the wire harness When these switches are disconnected the ignition key switch must be used to shut off the engine DO NOT continue to operate the machine with the throttle safety switch disconnected Return the machine to an authorized POLARIS dealer for service as soon as possible 79 OPERATION Electronic Reverse PERC Electronic reverse will activate only if the engine RPM is below 4000 WARNING Improper reverse operation even at low speeds may cause loss of control resulting in serious injury or death Damage will occur to the gearcase or transmission if shifting is attempted when the engine is operating above idle speed Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle Look behind the snowmobile before and while backing Avoid sharp turns Apply throttle slowly
80. ng on hard packed snow ice or when crossing roads steering and braking ability are greatly reduced Reduce speed and allow extra space to turn or stop To maintain vehicle control on ice or hard packed surfaces you should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for long periods Do not leave brake engaged for more than five minutes Before starting the engine check throttle brake and steering for proper oper ation Make sure hood is latched Be seated and in position to control the vehicle Oil injection system Use unmixed fuel only Check oil level when refueling 27 FEATURES ONOaARON gt 28 Nosepan Skis Front Bumper do not use for pulling or dragging the snowmobile Hood Headlight Windshield Mirrors Operator Seat Passenger Grab Handle Passenger Seat Backrest Cargo Bag Grab Handle Heater Switch Taillights Rear Bumper Snow Flap Track Passenger Footrest Suspension FEATURES 1 2 9 M Oo 0 Oo MFD Display Handlebar Grip Warmer Switch Thumbwarmer Switch Electronic Reverse Button MFD Control Headlight Dimmer Switch Parking Brake Lock Brake Lever 11 12 13 14 15 Ignition Switch Heated Windshield Power Plug Engine Stop Switch Throttle Contro
81. ng storage Whenever the machine is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the container running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel Do not allow the snowmobile to run out of fuel Electrical Connections Replace worn or frayed electrical wire and connectors Be sure wiring harness is properly secured away from sharp edges steering linkage moving parts and hot exhaust parts Track and Suspension Moderate track tension should be maintained during summer storage The snowmobile should be supported off the ground to allow the track to hang freely See illustration Transporting the Snowmobile Whenever the snowmobile is transported 1 Be sure the fuel cap and oil cap are installed correctly 2 Always tie the snowmobile to the transporting unit securely using suitable straps 3 Remove the ignition key to prevent loss 117 SPECIFICATIONS Capacities and Dimensions Body Style IQ Rider Capacity 2 Coolant Capacity 7 qts 6 6 1 Fuel Capacity 11 4 gal 43 2 1 Oil Capacity 3 4 qts 3 2 1 Gearcase Oil Capacity 9 oz 266 2 ml Length 127 in 323 cm Width 47 25 in 120 cm Height 52 in 132 cm Brake Type
82. nt 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 84 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 159mi 500 mi 1000 mi 2000 mi Pre 240 km 800 km 1600 km 3200 km Season CLUTCH Clutch Alignment Offset 104 l l I without belt Drive Belt Condition 105 l l l l Clutches 104 C C C Belt Tension
83. obile requires preventive measures to aid against deterioration and to prolong the useful life of many components See page 120 for the part numbers of POLARIS products Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be sure that corrosive salt and acids are removed from surfaces before beginning preservation with waxes and rust inhibitors grease oil or paint The snowmobile should be stored in a dry garage or shed out of direct sunlight and covered with a fabric snowmobile cover Plastic tarp may cause condensation to form and damage snowmobile components Controls and Linkage Lubricate all bushings and cables at the intervals outlined in the Periodic Maintenance Table beginning on page 85 Bearings Grease the jackshaft and drive shaft clutch side bearings with POLARIS Premium All Season Grease or a similar high quality grease to prevent corrosion Clutch and Drive System Remove the drive belt and store in a cool dry location Do not lubricate clutch components except the driven clutch shaft bushing as outlined in the service manual See your dealer 116 MAINTENANCE Extended Storage Engine Protection Proper preparation of the engine and fuel system is vital to the preven tion of rust and corrosion on precision engine parts duri
84. ody for snowmobile development recommends that snowmobiles conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE stan dards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufac turing quieter machines we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly INTRODUCTION Vehicle Identification Numbers Record your snowmobile s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a POLARIS key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Tunnel VIN Vehicle Model Number Tunnel VIN lower right side of the tunnel Engine Serial Number on recoil housing Key Number SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided
85. on Solution Poor quality fuel Replace with higher quality fuel Improper engine modifications Do not modify the engine Sensor Fail Safe The DET includes a sensor fail safe system to prevent the engine from damage if the sensor fails becomes disconnected or is unable to detect detonation The rider will experience a loss of power The sensor must be reconnected or repaired to regain full power See your POLARIS dealer for service if this occurs Tip The check engine light will flash six times if the sensor fails or becomes dis connected 35 FEATURES Instrumentation MFD Component Identification Item Analog if equipped Digital Gauge Check Engine Indicator Low Oil Indicator High Temp Indicator Brake Indicator Reverse Indicator co NI oy A WwW nm High Beam Indicator Digital Display Identification Item RPM or Speed Altitude if equipped Service Interval Degrees Celsius Degrees Fahrenheit Miles Kilometers Hours Trip 1 Trip 2 Trip F Service Label Altitude Label Fuel Level if equipped 4 3 2 Electrical System Voltage Level D D D D S 3 MAX Maximum MPH i bf if bf jue KPH or RPM gt D XD GD RIDE m MPH Miles per hour i bf bf bf I KPH Kilometers per hour a aa ap aD RPM Engine crankshaft revolutions per MAX MPH KPH He Fm minute AIR ENG ec F B 4 Air Temp if equippe
86. operly 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 exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may n
87. or other than black add brake fluid Sight Glass 101 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 Fill the 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 Always add brake fluid to the fill line as
88. ose nspect and adjust or replace Drive chain worn sprocket teeth bro ken SEE YOUR DEALER Poor low RPM per formance Worn drive belt nspect and replace as needed Excessive belt sheave clearance SEE YOUR DEALER Loose torque stop nspect and adjust Sticky clutch SEE YOUR DEALER Poor fuel quality Use 87 91 octane fuel or higher 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 122 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 com pression Mixture is too lean A main jet that is too small will cause seizure result ing in loss of power This indicates a major engine problem that must be repaired before op
89. ot apply to you if inconsistent with controlling state law 128 WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law Promotional Warranties Promotional warranties are sometimes offered by POLARIS These warranties can be but are not limited to Two year extended engine coverage Two year powertrain coverage Extended service contract If you selected any type of extended warranty coverage as part of a POLARIS retail pro gram please contact any authorized POLARIS dealer for additional information How to Obtain Warranty Service If your snowmobile requires warranty service you must take it to a POLARIS dealer authorized to repair POLARIS snowmobiles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility POLARIS recommends that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service Please work with your deal
90. pproved 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 61 THE PERFECT FIT Traction Products Studs Before equipping your snowmobile with traction products be aware of the laws in your area pertaining to the use of traction products Use only POLARIS traction products on your snowmobile Track war ranties are void if track damage or failure results from improper or excessive stud installation or the use of non POLARIS traction prod ucts See your dealer about installing studs and or carbides NOTICE Always install wear strips before installing studs Failure to install wear strips may result in cooler or tunnel damage See page 63 Never add shims to the wear strip Track damage will result because of lack of clearance between upper carrier wheels and track Use of studs longer than the recommended length on machines equipped with center coolers will result in center cooler damage or damage to the tunnel Track studding will enhance braking control on hard packed snow or ice but extreme caution is still required on such surfaces Steering abil ity may be reduced on hard packed snow or ice When studd
91. proper oil flow See your POLARIS dealer for recommended replacement parts 77 OPERATION Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly Pull the switch up to the RUN position to allow restarting Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position Stop Switch WARNING Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a carburetor throttle system malfunction immediately push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer 78 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 stops abruptly when the throttle lever is released l 2 Tip Tip Turn the ignition switch to OFF Visually inspect the throttle cable and throttle body to determine what caused the safety switch to activate Test the throttle lever by compressing and releasing it several times The lever a
92. r items The maximum weight capacity for the cargo area is 30 Ibs 14 kg Always secure cargo before operating Do not exceed the weight limit Do not allow a passenger to sit on the seat back or the cargo area Seat Latch Push down on the seat latch lever which is located at the lower rear of the passenger seat 2 Liftup the seat and remove it from the chassis 3 Reverse the procedure to reinstall the seat Press down firmly on both sides of the seat to engage the latch Verify that the latch is engaged by firmly pulling the seat upward 31 FEATURES Passenger Grab Handle On some models the position of the passenger grab handles can be adjusted for rider preference Unscrew and remove the knob assemblies that secure the grab han dles 2 Reposition the grab handles to one of the three available positions on the grab handle tube between the operator seat and the passenger seat 3 Reinstall the knob assemblies and tighten securely 32 FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system if equipped allows you to adjust the handlebar position to fit your style of riding Some models have five 5 adjustment positions Other models have seven 7 positions WARNING If your snowmobile has five adjustment positions do not remove the RIDER SELECT lockout Your POLARIS snowmobile has been engineered for this range of adjustability Removing this lockout and using
93. r power DO NOT MODIFY YOUR MACHINE The snowmobile may become aerody namically unstable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety haz ard and lead to bodily injury The warranty on your entire machine is terminated if any equipment has been added or any modifications have been made to increase the speed or power of the snowmobile SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation bd Stay Clear of Engine Never attempt adjustments with the engine running Turn off the igni tion raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation WARNING Serious injuries may result if hands feet or clothing become entangled in the track Be alert when riding and remain properly seated to stay clear of the track Never hold the snowmobile up or stand behind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments 10 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and b
94. r when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehi cle POLARIS also recommends that you use only Pure POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the POLARIS Warranty Department at 1 888 704 5290 134 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM
95. raps 2 Relocate the straps to the desired position 3 Reinstall the nuts and washers Tighten securely 56 THE PERFECT FIT IQ Rear Suspension Adjustments Suspension Coupling On all POLARIS snowmobile rear suspensions there are two torque arms that control the movement of the rail beam Prior to the advent of suspension coupling these torque arms could move independently of each other Rear suspension coupling links the movement of the front and rear torque arms to each other There are two types of rear suspen sion coupling Front To Rear Coupling and the Front Rear Scissor Stop FRSS The front rear scissor stop FRSS couples the movement of the front torque arm with the rear torque arm and limits the amount of indepen dence 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 reducing kickback The factory setting is usually adequate for all riders and conditions 57 THE PERFECT FIT IQ Rear Suspension Adjustments Rear To Front Coupling and the Rear Rear Scissor Stop RRSS The rear rear scissor stop RRSS couples the movement of the rear torque arm with the front torque arm and limits the amount of indepen dent movement between the rear torque and the front torque
96. recommended 7 After bleeding is complete refill the reservoir to the proper level See page 101 8 Reinstall the gasket and cover 102 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 Remove the plenum cover Bulb ing from the headlight assembly Spring Lift the rubber boot to expose the bulb a Push down on the spring to Hamess release it from the housing With the wire harness attached to the bulb with draw the bulb from the housing Grasp the bulb by its metal base and carefully separate the bulb from the harness Installing Halogen Bulbs i 2 3 4 5 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 31 Replacing Taillight Bulbs 1 2 3 Remove the screws securing the taillight lens Remove the lens Push the bulb inward and turn it counter clockwise to remove it Install a new bulb Push the bulb inward and turn it clockwise to secure it Reinstall the taillight lens 103 MAINTENANCE Clutch Syste
97. rol and serious injury or death Always stop the snowmobile before attempting to adjust the steering system 1 Stop the snowmobile 2 Press the release button and move the handlebar forward or rearward to the desired position WARNING Do not lubricate the RIDER SELECT mechanism Doing so could cause loss of control and result in serious injury or death The RIDER SELECT mechanism is lubricated for life at the factory WARNING Some aftermarket accessories including windshields and cargo bags may interfere with the handlebar Such accessories could limit your ability to steer the vehicle and or may contact the brake lever This could lead to loss of control resulting in serious injury or death Always be sure that accessories do not contact the handlebar or brake lever at any steering position and at any RIDER SELECT position 34 FEATURES Detonation Elimination Technology DET The DET system prevents damage to the engine from detonation by automatically reducing the engine timing and adding fuel whenever the sensors detect detonation You may notice decreased engine RPM and performance when DET is activated but in most cases DET activation is temporary and the timing will return to normal automatically In extreme conditions the DET sys tem retards timing and holds it in a retarded state If this occurs replace the fuel with recommended fuel or see your POLARIS dealer for ser vice Cause of DET Activati
98. sulting in serious injury or death Always inspect for track damage before operating the snowmobile Follow these steps to ensure proper warm up of the engine drive train and track 1 Use an appropriate stand to securely support the rear of the snow mobile at the rear bumper The track should be approximately 4 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions Tip It will take longer to warm up the track sufficiently during colder outdoor temperatures 4 Release the throttle apply the brakes shut off the engine and lower the snowmobile to the ground 5 Grasp the skis by their front loops and move them from side to side to loosen snow and ice 74 OPERATION Fuel Safety Gasoline is highly flammable and explosive under certain conditions e e e 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 If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can c
99. t 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 The following are registered trademarks of POLARIS Industries Inc POLARIS PERC IQG RIDER SELECT 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 LXT Owner s Manual P N 9924222 TABLE OF CONTENTS Introduction sis vlra 9 REGE SEA ERSSEE ES 5 This section contains helpful information for owners and drivers and illustrates the location of import
100. t the vehi cle is designed for one operator and one passenger only WARNING 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 your snowmobile Snowmobiles designed for two riders should never be operated with more than two people on board When traveling with a passenger it s the driver s responsibility to operate the snowmobile safely Slow down Control becomes more difficult with two people on board More space is required to make turns and longer distances are necessary for stopping 13 SAFETY Operator Safety Disabled Operators Safe operation of this rider active vehicle requires good judgement and physical skills WARNING Operators with cognitive or physical disabilities have an increased risk of loss of control which could result in serious injury or death Do not allow disabled persons to operate this vehicle Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer Do not exceed carrier and rack weight limits and do not allow a passenger to sit on the seat back or the cargo carrier 14 SAFETY Operator Safety Excessive Speed WARNING High speed driving especially at night could result in serious injury or death Always reduce sp
101. tenance Table beginning on page 85 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the life of the sus pension For more information about suspension lubrication and adjust ments see your POLARIS dealer IQ Comfort Rear Suspension er lie CN qc 9 ZZ f 88 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel This should take approximately two pumps Do not use more than four pumps Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars to the left and lubricate liberally as shown Front Suspension The front suspension and steering components do not require lubrica tion 89 MAINTENANCE Chaincase Oil Check the chaincase oil level at the intervals outlined in the Periodic Main tenance Table beginning on page 85 The sight glass 1 is located on the lower rear of the chaincase Maintain the oil level at or slightly below the center of the sight glass 2 Change the chain case oil after the first 500 miles 800 km then every 1000 miles 1600 km or seasonally POLARIS recommends the use of POLARIS Synthetic Chaincase Lube See page 120 for the part numbers of POLARIS products Oil Ch
102. ter the display begins to flash 4 When the display stops flashing release the button The service interval has been reset 46 FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder To reset the reminder at a new interval l 2 3 4 Enter the History Program Press and release the SET button until the service interval screen is active Press and hold the SET button for five seconds until the hours begin to flash Immediately release the button Press the button again up to five times to advance the reminder in 50 hour increments Tip The maximum interval is 250 hours X 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 47 FEATURES Instrumentation MFD Battery Replacement Models equipped with the clock feature have a battery to power the clock If the clock function of the MFD isn t working properly replace the battery Replace ment batteries are available from your dealer 1 2 Tip 48 Remove the plenum from the under side of the hood Locate the black battery compart ment It has a red wire and a brown wire with a white stripe It s located about three inches down the main harness from the point where the harness connects to the MFD Cut the plastic cable tie from th
103. to oil movement in the bottle but when the light comes on and remains on add the recom mended oil before further operation See page 72 for oil recommenda tions 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 Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage They may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All POLARIS oils are compatible with each other Always maintain the oil level above the tank s low level line This is especially important when the snowmobile is operated in mountainous terrain Maintaining the proper oil level will prevent system aeration and possible loss of pumping action which could result in engine damage NOTICE Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of POLARIS 2 cycle oils for your snowmobile Never mix brands Operating the snowmobile without proper engine lubrication can result in serious engine damage Always check the oil level when refueling Low Oil Level Always do a visual check of the oil level when refueling When the oil reaches the low level mark add the recommended oil to the tank The POLARIS oil cap on the oil bottle is vented to allow
104. ts 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 value It will adjust up to 1300 ft 396 m above the calibrated altitude Once the 1300 ft 396 m offset has been reached the next adjustment is 1300 ft 396 m from the calibrated altitude and 50 ft 15 m will be added to the altitude each time the SET button is pressed 6 Press and release the MODE button to set the reading at the adjusted value If the MODE button is not pressed within ten seconds the gauge will automatically save the new entry 44 FEATURES Instrumentation MFD Digital Display Programs History Program The History Program automatically displays electrical system voltage level and fuel level 1f equipped While in the History mode press the SET button to view maximum vehicle speed maximum engine rpm or the current service interval set ting The gauge automatically logs the maximum speed and engine rpm even if the History Program is not currently displayed The History Program will display the history of the Maximum Speed Maximum R
105. vel and fuel level if equipped On machines equipped with altimeter sensor and ambient air temperature sensors altitude and ambient air temperature will display as additional screens in the engine program Press the SET button to dis play the ambient air temperature and altitude screens Use the following procedures to make changes to these screens Hour Meter 3 The hour meter records the total hours of engine operation since manufacture This meter cannot be reset m E T t ENG F ngine Temperature hr 28e 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 1 Enter the Engine Program 2 Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement 43 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 1s active 3 Press and hold the SET button for five seconds When the digi
106. water currents may result in uneven ice thickness You may drown if you break through the ice Never travel on frozen bodies of water unless you have first verified that the ice is suffi ciently thick to support the weight and moving force of the snowmobile you and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice condi tions and thickness over your entire route Snowmobile operators assume all risk associated with ice conditions on frozen bodies of water 16 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain Take an avalanche class Travel with experienced people Travel on designated trails Make sure each person is equipped with a shovel probe and avalanche beacon You don t have to be snowmobiling on a slope for an avalanche to occur Be aware that all of the snow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in mountainous terrain Before riding in mountainous terrain call or log on to your local ava lanche advisory to get current weather and snow stability information For more information about avalanche training and avalanche condi tions contact local law enforcement
107. will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 84 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals AWARNING Driving a snowmobile requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger They will reduce your alertness and slow your reaction time Snowmobiles are capable of traveling at high speeds Use extra caution to ensure operator safety Make sure your snowmobile is in excellent operating condition at all times Always check major and vital safety components before every ride All POLARIS snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed o
108. with the proper gap Refer to the spec ifications section beginning on page 118 e Use only resistor type spark plugs Torque spark plugs to 18 22 ft Ibs 24 30 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 92 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 carburetor throttle body adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil or use of non recommended injection oil Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counter clockwise to remove 3 Reverse the procedure for spark plug installation 4 Torque to 18 22 ft lbs 24 30 Nm
109. wmo bile Steering System WARNING Ice and snow build up may interfere with the steering of your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering If difficulty is encountered remove ice and snow build up that may be obstructing the steering linkage If your snowmobile is equipped with RIDER SELECT perform this check in both the full up and full down steering positions 66 PRE RIDE INSPECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine Brake Lever Travel Squeeze the brake lever It should move no closer to the handgrip than 1 2 1 3 cm A smaller distance indicates low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 102 Brake Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 101 1 2 1 3 cm Check for the presence of air in the fluid system See page 102 for more information 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
110. wner 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 make sure both are functioning properly Squeeze the throttle lever to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle position without binding or hesitation If the throttle does not func tion smoothly or if you discover excessive lever freeplay DO NOT start the engine Have the throttle serviced immediately Throttle Safety Switch Test the throttle safety switch system before the snowmobile is operated See page 78 for procedure Seat Latches Ensure that the seat latches are securely in place before every use of the snowmobile Recoil Rope Inspect the recoil rope and handle for excessive wear and make sure the knot securing the rope inside the handle is secure If excessive wear is found see your POLARIS dealer for replacement 65 PRE RIDE INSPECTIONS Before Starting the Engine Hood Latches The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions Under no circumstances should your snowmobile be operated with the hood open or removed Always ensure that the hood straps are in good condition and that the latches are securely in place before operating the sno

Polaris 600 INDY Offroad Vehicle User Manual

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